Protein-containing foams, manufacture and use thereof

ABSTRACT

The invention relates generally to protein-containing polyurethane foams, methods and compositions for making the polyurethane foams, and articles comprising the polyurethane foams.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/719,721, filed Mar. 8, 2010, which claims the benefit of and priorityto co-pending U.S. Provisional Patent Application Ser. No. 61/246,215,filed Sep. 28, 2009, to co-pending U.S. Provisional Patent ApplicationNo. 61/246,208, filed Sep. 28, 2009, and to co-pending U.S. ProvisionalPatent Application No. 61/157,944, filed Mar. 6, 2009, the entirecontents of each of which are incorporated by reference herein.

FIELD OF THE INVENTION

The invention relates generally to protein-containing foams, theirmanufacture and their use.

BACKGROUND

Foams are used in a wide variety of industrial and consumer applicationsincluding, for example, foam insulation, packaging foams, crash padding,carpet backings, decorative foams for simulated wood furnishings, etc.Utilization of these foams continues to grow throughout the world. Thegrowth can be attributed to, among other things, their light weight,good strength to weight ratio, their insulation and sound proofingproperties, and the energy absorbing properties of foams. Polyurethanefoams are very popular and can be made in a variety of different forms.For example, polyurethane foam can be fabricated in a flexible,semi-rigid, or rigid form with flexible foams generally being softer,less dense, more pliable, and more subject to structural reboundsubsequent to loading than rigid foams.

The preparation of polyurethane foams have been discussed extensively inthe foam arts. Nevertheless, a common approach for making polyurethanefoams is by reaction of a polyol and an isocyanate, which forms thebackbone urethane group. Typically, a blowing agent, for example, aninert gas or a compound that creates gas, is used to create cells withinthe foam. Additional modulating agents, for example, catalysts andsurfactants can be added during production to modulate the properties ofthe resulting foam product.

Recently, efforts have been underway to replace or reduce the use ofpolyester or polyether polyols in the production of polyurethane foams,with a more versatile, renewable, less costly, and more environmentallyfriendly components. For example, foams have been produced using fattyacid triglycerides derived from vegetables. Because such materials arerenewable, relatively inexpensive, versatile, and environmentallyfriendly, they are desirable as ingredients for foam manufacture.

However, there still exists a need for the development of renewable,less costly, and more environmentally friendly agents that can modulatethe properties of foam. For example, renewable materials that can beused to improve the properties of foam, such as a higher foam rise,uniform cell structure, and/or a lower density foam, would beadvantageous. Of particular value would be a material present in wasteby-products, which can be obtained inexpensively and in largequantities.

SUMMARY

The invention is based, in part, upon the discovery that certain proteincompositions derivable from a variety of starting materials, forexample, waste plant biomass, can be used to modulate the properties offoam, and can, for example, make lower density foams containing agreater number of smaller, more uniform cells.

In one aspect, the invention provides an isolated, water-solublepolypeptide composition capable of stabilizing a polyurethane-basedfoam. The isolated, water-soluble polypeptide fraction comprises one ormore of the following features: (a) an amide-I absorption band betweenabout 1633 cm⁻¹ and 1680 cm⁻¹, as determined by solid state FourierTransform Infrared spectroscopy (FTIR); (b) an amide-II band betweenapproximately 1522 cm⁻¹ and 1560 cm⁻¹, as determined by solid stateFTIR; (c) two prominent 1° amide N—H stretch absorption bands centeredat about 3200 cm⁻¹, and at about 3300 cm⁻¹, as determined by solid stateFTIR; (d) a prominent cluster of protonated nitrogen nuclei defined by¹⁵N chemical shift boundaries at about 94 ppm and about 100 ppm, and ¹Hchemical shift boundaries at about 7.6 ppm and at about 8.1 ppm, asdetermined by solution state, two-dimensional proton-nitrogen coupledNMR; (e) an average molecular weight of between about 600 and about2,500 Daltons; (f) an inability to stabilize an oil-in-water emulsion,wherein, when an aqueous solution comprising 14 parts by weight ofprotein dissolved or dispersed in 86 parts by weight of water is admixedwith 14 parts by weight of polymeric diphenylmethane diisocyanate(PMDI), the aqueous solution and the PMDI produce an unstable suspensionthat macroscopically phase separates under static conditions within fiveminutes after mixing; (g) the water-soluble polypeptide composition iscapable of stabilizing a polyurethane-based foam relative to apolyurethane-based foam created from the same starting compositionlacking the water-soluble protein composition; and (h) the water-solublepolypeptide composition is capable of reducing the density of apolyurethane-based foam by at least 5% (for example, at least 10%, 20%,30%, 40%, 50%, 60%, 70%, 80%, 90% or 100%) relative to apolyurethane-based foam created from the same starting composition butthat lacks the water-soluble polypeptide composition.

In another aspect the invention provides a method for preparing anisolated, water-soluble polypeptide composition for use in thepreparation of a foam. The method comprises: (a) dispersing a proteincontaining starting material in an aqueous solution at a pH greater thanabout 6.5 for at least 5 minutes to produce a suspension containingparticulate matter; (b) after step (a), optionally reducing the pH toabout 4.0-5.0; and then separating the aqueous solution from theparticulate matter thereby to harvest a solution enriched for thewater-soluble polypeptide composition described herein.

In certain embodiments, the method further comprises one or more of: (i)prior to step (a), digesting the starting material with an enzyme; (ii)after step (a), digesting the suspension with an enzyme; (iii) afterstep (b), digesting the suspension with an enzyme; or (iv) after step(c), digesting the solution enriched for the water-soluble polypeptidecomposition with an enzyme. Useful enzymes include, for example, aserine-, leucine-, lysine-, or arginine-specific protease. The methodoptionally further comprises drying the water-soluble polypeptidecomposition harvested in step (c).

In each of the these aspects, the water-soluble protein composition canbe derived from animal material (for example, milk and whey, fishmeal,animal tissue) or from plant material (for example, corn, wheat,sunflower, cotton, rapeseed, canola, castor, soy, camelina, flax,jatropha, mallow, peanuts, algae, legumes, palm, tobacco, sugarcanebagasse, and combinations thereof). In certain other embodiments, thestarting material (the biomass) in the process for making thewater-soluble protein composition can be whey, canola meal, canolaprotein isolate, castor meal, castor protein isolate, soy meal, soyprotein isolate, or a combination thereof.

In another aspect, the invention provides a foam produced using thewater-soluble protein composition described herein. The foam can be apolyurethane foam that comprises the reaction product of a mixturecomprising: (a) the water-soluble polypeptide composition describedherein; (b) an isocyanate-based reactant; and (c) an optionalisocyanate-reactive compound. In certain embodiments, the mixtureoptionally can further comprise, among other things, a surfactant and/ora catalyst and/or a blowing agent.

In another aspect, the invention provides a polyurethane foam comprisinga reaction product of a mixture comprising: (a) a protein containingcomposition, (b) an isocyanate-based reactant, and (c) an optionalisocyanate-reactive component, wherein the protein containingcomposition is capable of reducing the density of the polyurethane foamby at least 5% (for example, by at least 10%, 20%, 30%, 40%, 50%, 60%,70%, 80% or 90%) relative to a polyurethane foam produced from the samemixture but lacking the protein containing composition. In certainembodiments, the mixture optionally can further comprise, among otherthings, a surfactant and/or a catalyst and/or a blowing agent.

In another aspect, the invention provides a polyurethane foam comprisinga reaction product of a mixture comprising: (a) an isolated proteincontaining composition, wherein the protein containing composition iscapable of dispersing PMDI in an aqueous medium, (b) an isocyanate-basedreactant, and (c) an optional isocyanate-reactive component. The proteincontaining composition comprises a water-insoluble/water dispersibleprotein fraction either alone or in combination with a water-solubleprotein fraction. In certain embodiments, the mixture optionally canfurther comprise, among other things, a surfactant and/or a catalystand/or a blowing agent.

In each of the foregoing aspects, the isocyanate-based reactant can bean organic polyisocyanate, for example, a polymeric diphenylmethanediisocyanate, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate,benzene diisocyanate, m-xylylene diisocyanate, 1,4-phenylenediisocyanate, 1,3-phenylene diisocyanate, 4,4′-diphenyl diisocyanate,4,4′-diphenyldimethylmethane diisocyanate, hexamethylene diisocyanate,tolidine diisocyanate, dianisidine diisocyanate, 1,5-naphthalenediisocyanate, 1,4-cyclohexane diisocyanate, or a combination thereof.Alternatively or in addition, the isocyanate-based reactant comprises aurethane, allophanate, urea, biuret, carbodiimide, uetonimine,isocyanurate, or a combination thereof. In certain embodiments, theisocyanate-based reactant can be a polymeric diphenylmethanediisocyanate.

The isocyanate-reactive compound can be a compound nucleophilicallyreactive with an isocyanate. For example, the isocyanate-reactivecompound can be a compound having, for example, a hydroxyl group or anamino group capable of reacting with the isocyanate. In certainembodiments, the isocyanate-reactive compound is a polyol, for example,polyol derived from castor oil, linseed oil, or soy oil. In certainother embodiments, the isocyanate-reactive compound is a polyolinitiated with a compound selected from the group consisting ofglycerol, trimethylopropane, triethanolamine, pentaerythritol, sorbitolsucrose, diamine, tolylene diamine, diaminodiphenylmethane, apolymethylene polyphenylene polyamine, ethanolamine, diethanolamine, ora mixture thereof. Furthermore, the isocyanate reactive compound caninclude a water-insoluble/water dispersible polypeptide composition,used alone or in combination with any of the aforementionedisocyanate-reactive compounds. The water-insoluble/water dispersiblepolypeptide composition has the ability to disperse with theisocyanate-based reactant and to become an integral structural componentof the resulting cured foam. However, unlike the water-solublepolypeptide proteins, the water-insoluble polypeptide compositionstypically do not reduce the density of the resulting foam.

Alternatively or in addition, the isocyanate-reactive compound can be ahydroxyl terminated polythioether, polyamide, polyesteramide,polycarbonate, polyacetal, polyolefin or polysiloxane, or a polyesterobtained by condensation of a glycol or higher functionality polyol witha dicarboxylic acid. In certain embodiments, the isocyanate-reactivecompound is polyoxypropylene glycol, polypropylene oxide-ethylene oxide,propylene glycol, propane diol, glycerin, an amine alkoxylate, or amixture thereof. In certain other embodiments, the isocyanate-reactivecompound is polyoxypropylene glycol.

In certain embodiments, the foam has a density in the range of fromabout 0.01 g/cm³ to about 0.5 g/cm³, as determined by ASTM D-7487. Incertain embodiments, the foam can have a density that is from 5% to 80%less dense than a foam created from the same starting composition thatlacks the water-soluble polypeptide composition described herein orprotein containing composition that contains an amount of awater-soluble protein sufficient to reduce the density of the resultingfoam. In certain other embodiments, the foam cream time, as defined byASTM D-7487, is less than one minute. In certain other embodiments, thefoam free rise height, as determined by ASTM D7487, is greater than thefoam free rise height of a foam created from the same startingcomposition lacking the water-soluble polypeptide composition describedherein or protein containing composition that contains an amount of awater-soluble protein sufficient to reduce the density of the resultingfoam. For example, the foam free rise height can be at least 5% greaterthan the foam free rise height of a foam created from the same startingcomposition lacking such proteins. In certain other embodiments, thefoam has a larger number of smaller, more uniform cells when compared toa foam created from the same starting composition lacking thewater-soluble polypeptide composition described herein or a proteincontaining composition that contains an amount of a water-solubleprotein sufficient to reduce the density of the resulting foam.

In another aspect, the invention provides a method of producing apolyurethane foam, which comprises the steps of: (a) mixing a proteincontaining composition (for example, the water-soluble polypeptidecomposition as described herein) and an isocyanate-based reactant toproduce a mixture; and (b) permitting the mixture to produce apolyurethane foam. Although, the water-soluble fraction does not need tobe isolated to be effective in reducing the density of the resultingfoam, under certain circumstances it is desirable to separate thewater-soluble and water-insoluble protein fractions and to add them incontrolled ratios to modulate the properties of the resulting foams. Incertain embodiments, the mixture in step (a), further comprises anisocyanate-reactive compound. The isocyanate-based reactant and theisocyanate-reactive compound can be the same as those described abovefor the other aspects of the invention.

The mixture in step (a) optionally further comprises a blowing agent ora compound that forms a blowing agent. It is understood that, undercertain circumstances, water is capable of forming a blowing agent. Thewater-soluble protein can be dissolved, dispersed or suspended in water,in a solution containing the isocyanate-based reactant, or in a solutioncontaining the isocyanate reactive material.

In certain embodiments, the mixture in step (a) can further comprise acatalyst that facilitates generation of the foam. Exemplary catalystsinclude, for example, dibutyltin dilaurate, dibutyltin diacetate,triethylenediamine, 2,2′-dimethylamino diethyl ether, 2-dimethylaminoethanol, stannous octoate, potassium octoate, an alkali metal salt of acarboxylic acid, or a combination thereof. Alternatively or in addition,the mixture in step (a) further comprises a surfactant, for example, apolyether silicone. Alternatively or in addition, the mixture in step(a) can further comprise an additive selected from the group consistingof a fire retardant, a filler, a reinforcement, a smoke suppressant, abiocide, an inert plasticizer, an antistatic agent, and combinationsthereof.

In certain embodiments, the isocyanate-based reactant constitutes fromabout 10% (w/w) to about 90% (w/w) of the starting materials used toprepare the foam. In certain other embodiments, the isocyanate-reactivecompound constitutes from about 10% (w/w) to about 90% (w/w) of thestarting materials used to prepare the foam. In certain otherembodiments, the protein containing composition (e.g., the water-solublepolypeptide composition) constitutes from about 0.01% (w/w) to about 50%(w/w) of the starting materials used to prepare the foam. In certainother embodiments, the foam is produced at an Index in the range fromabout 250% to about 800%.

In another aspect, the invention provides a premix for preparing apolyurethane foam, comprising: a protein containing composition (forexample, a water-soluble polypeptide composition described herein, awater-insoluble/water dispersible polypeptide composition, or a mixturethereof) and an isocyanate-based reactant. The protein containingcomposition is characterized as being capable of reducing the density ofthe polyurethane foam by at least 5% (for example, by at least 10%, 20%,30%, 40%, 50%, 60%, 70%, 80% or 90%) relative to a polyurethane foamproduced from the same mixture but lacking the protein containingcomposition. The pre-mix can also include, among other things, anisocyanate-reactive compound, a blowing agent or a compound that forms ablowing agent, a surfactant, and a catalyst that facilitates generationof the foam.

The isocyanate-based reactant, the isocyanate-reactive compound, theblowing agent or the compound that forms the blowing agent, thesurfactant, and the catalyst can be the same as those discussedhereinabove. In certain embodiments, the isocyanate-based reactantconstitutes from about 10% (w/w) to about 90% (w/w) of the premix. Incertain embodiments, the isocyanate-reactive compound constitutes fromabout 10% (w/w) to about 90% (w/w) of the premix. In certain otherembodiments, the protein containing composition (for example, thewater-soluble polypeptide composition) constitutes from about 0.1% (w/w)to about 99% (w/w) of the starting materials used to prepare the foam.

In another aspect, the invention provides an article comprising the foamdescribed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, features and advantages of theinvention will become apparent from the following description ofpreferred embodiments, as illustrated in the accompanying drawings. Thedrawings are not necessarily to scale, with emphasis instead beingplaced on illustrating the principles of the present invention, inwhich:

FIG. 1 is a flow chart showing the steps of an exemplary method forproducing isolated polypeptide compositions useful in the practice ofthe invention;

FIG. 2 shows overlaid solid state FTIR spectra for water-soluble andwater-insoluble protein fractions isolated from digested castor lot5-90;

FIG. 3 shows solid state FTIR spectra of isolated water-soluble andwater-insoluble fractions from digested castor, where the carbonyl amideregion is expanded;

FIG. 4 shows solid state FTIR spectra of isolated water-soluble andwater-insoluble fractions from digested castor where the N—H stretchingregion is expanded;

FIG. 5 shows overlaid solid state FTIR spectra of isolated fractionsfrom castor protein (lot 5-94), showing an expansion of the carbonylamide region (water-soluble fraction, and water-insoluble/waterdispersible fraction);

FIG. 6 shows the solid state FTIR spectra of isolated water-soluble andwater-insoluble fractions from castor protein (lot 5-94), where the N—Hand O—H stretch regions are expanded;

FIG. 7 shows overlaid solid state FTIR spectra of the isolatedwater-insoluble/water dispersible fractions from castor protein (lot5-94) and from enzyme digested castor (lot 5-90);

FIG. 8 shows overlaid solid state FTIR spectra of isolated water-solubleand water-insoluble fractions from digested soy, where the carbonylamide region is expanded, where the spectra were vertically scaled toachieve equivalent absorbance intensities for the amide-I carbonylstretch;

FIG. 9 shows overlaid solid state FTIR spectra of isolated water-solubleand water-insoluble fractions from digested soy, where the N—Hstretching region is expanded;

FIG. 10 shows overlaid solid state FTIR spectra of isolatedwater-soluble polypeptide fractions from digested soy and digestedcastor;

FIG. 11 shows overlaid solid state FTIR spectra of isolatedwater-insoluble fractions from digested soy and soy flour;

FIG. 12 shows overlaid solid state FTIR surface ATR spectra of theisolated water-insoluble/dispersible fractions from multiple proteinsamples (digested soy lot 5-81, soy flour, castor protein isolate lot5-94, digested castor lot 5-90) where the carbonyl amide region isexpanded;

FIG. 13 is a two-dimensional HSQC ¹H-¹⁵N NMR spectrum for digestedcastor (lot 5-83) in d6-DMSO, showing two regions of interest denotedRegion A and Region B;

FIG. 14 is a two-dimensional HSQC ¹H-¹⁵N NMR spectrum forwater-insoluble/dispersible polypeptide fraction derived from digestedcastor (lot 5-83) in d6-DMSO, again showing Region A and Region B;

FIG. 15 shows polyurethane foams produced according to the procedures inExample 5.

FIG. 16 shows polyurethane foams produced according to the procedures inExample 9.

FIG. 17 shows polyurethane foams produced according to the procedures inExample 10, where FIG. 17(A) shows a 9:10 ratio of polyisocyanate:PMDIand FIG. 17(B) shows a 10:10 ratio of polyisocyanate:PMDI.

FIG. 18 shows polyurethane foams produced according to the procedures inExample 11.

FIG. 19 shows polyurethane foams produced according to the procedures inExample 13.

DETAILED DESCRIPTION OF THE INVENTION

The invention is based, in part, upon the discovery that certain proteinfractions derivable from a variety of starting materials (for example,waste plant biomass) can be used to modulate the properties of foam, andcan, for example, make lower density foams containing a greater numberof smaller, more uniform cells. The invention provides an isolated,water-soluble polypeptide composition capable of stabilizing apolyurethane-based foam, protein-containing polyurethane foams, methodsand compositions for preparing protein-containing polyurethane foams,and articles comprising said polyurethane foams. The isolatedwater-soluble polypeptide composition can be isolated from a variety ofsources, for example, plant matter (such as biomass produced as a wasteby-product of the agricultural industry) or animal matter (for example,milk or whey, fish meal, or animal tissue).

It has been discovered that the certain protein fractions (which caninclude isolated water-soluble protein compositions and crude proteincontaining compositions that contain a certain amount of thewater-soluble proteins) can be added to polyurethane foam-formingcompositions to alter the properties of the resulting polyurethane foam.For example, the resulting foam can have, for example, lower densityand/or smaller, more uniform cell size relative to foams generated fromthe same starting materials that lack the protein fraction. As a result,it is possible to produce foams that require less raw material (forexample, isocyanate-based reactants and/or isocyanate-reactivecompounds) to fill a given volume. As a result, it is possible toprepare foams with the desired physical characteristics cheaper thanfoams that lack the proteins, and it also is possible to produce foamswithout the use of known polyurethane foam surfactants in theformulation. These protein-containing polyurethane foams can be preparedby mixing certain protein compositions described herein, anisocyanate-based reactant and an optional isocyanate-reactive compoundto produce a premix that generates a foam. Further description of theprotein compositions capable of stabilizing a polyurethane-based foam,protein-containing polyurethane foams, methods and compositions forpreparing such protein-containing polyurethane foams, and articlescomprising said polyurethane foams are provided below.

I. Polypeptide Compositions

Different protein fractions derivable from animal and plant biomass havedifferent physical and chemical properties. As a result, the proteinscan be used to modulate the desired characteristics of the resultingfoams. The water-soluble protein fractions described herein providepolyurethane foams having lower density and/or smaller, more uniformcell size when compared to foams prepared without the water-solubleprotein fraction. In certain embodiments, a water-insoluble/waterdispersible protein fraction can also be further added to the premixthat generates the foam. Addition of water-insoluble/water dispersibleprotein fraction further modifies the properties of the foam producedfrom the premix. The addition of water-insoluble/water dispersibleproteins can provide structural rigidity to, and/or modulate the densityof, the resulting foam. In addition, both thewater-insoluble/water-dispersible protein fraction and the water-solubleprotein fraction can be used alone or in combination to produceadhesives, which are described in detail in U.S. patent application Ser.No. 12/719,521, filed on Mar. 8, 2010, the disclosure of which isincorporated by reference herein.

The terms “protein” and “polypeptide” are used synonymously and refer topolymers containing amino acids that are joined together, for example,via peptide bonds or other bonds, and may contain naturally occurringamino acids or modified amino acids. The polypeptides can be isolatedfrom natural sources or synthesized using standard chemistries.Furthermore, the polypeptides may be modified or derivatized by eithernatural processes, such as post-translational processing, or by chemicalmodification techniques well known in the art. Modifications orderivatizations may occur anywhere in the polypeptide, including, forexample, the peptide backbone, the amino acid side-chains and the aminoor carboxyl termini. Modifications include, for example, cyclization,disulfide bond formation, demethylation, deamination, formation ofcovalent cross-links, formation of pyroglutamate, formylation,gamma-carboxylation, glycosylation, GPI anchor formation, hydroxylation,iodination, methylation, myristolyation, oxidation, pegylation,proteolytic digestion, phosphorylation, etc. As used throughout, theterm “isolated” refers to material that is removed from its originalenvironment (e.g., the natural environment if it is naturallyoccurring).

The starting material for producing the isolated polypeptidecompositions, which can be a meal or a protein isolate, can be derivedfrom plant material (for example, one or more of corn, wheat, sunflower,cotton, rapeseed, canola, castor, soy, camelina, flax, jatropha, mallow,peanuts, palm, tobacco, sugarcane bagasse, and algae) and/or animalmaterial (for example, milk, whey, fish meal, animal tissue). It isunderstood that the water-soluble protein fraction can be produced in avariety of ways, for example, as described throughout the Examples.

For example, water-soluble proteins can be isolated by washing plant oranimal material with water, and simply harvesting the proteins thatdissolve in the water washes. It is understood, however, that theresulting washes may contain compounds other than water-solubleproteins, for example, water soluble carbohydrates such as starches andsugars, etc. However, given that the ratio of the water-soluble proteinfraction to the water-insoluble/water dispersible protein fraction canvary depending on a number of factors such as the source of the startingmaterial as well as any processing steps that may already have beencarried out on the starting material, and given that thewater-insoluble/water dispersible polypeptide does not facilitate thedensity reduction and may even diminish this effect, it is preferable toseparate the two different polypeptide fractions and then to add themtogether in controlled manner to control the physical and chemicalproperties of the resulting foam, and to improve the reproducibility ofthe resulting foam. If density reduction is not required in the foam ofinterest, then it is understood that it is possible to reduce oreliminate altogether the water-soluble polypeptide from the composition,and to use the water-insoluble/water dispersible polypeptide as theexclusive protein-based component in the formulation. This can bedesirable when it is desirable to produce a foam with equivalent orhigher density (which affects modulus, strength, permeability, etc.),than a comparable foam that contains no protein, or a comparable foamthat contains any amount of the water-soluble polypeptide fraction.

Similarly, it is understood that the water-insoluble/water dispersibleprotein fraction can be produced by a number of approaches, which aredescribed in detail throughout the Examples and in co-pending U.S.patent application Ser. No. 12/719,521, filed on Mar. 8, 2010, thedisclosure of which is incorporated by reference herein. For example, acrude water-insoluble/water dispersible protein fraction can be isolatedfrom soy protein isolate by washing with water to remove water-solubleproteins and water-soluble components from the soy protein isolate.Although the crude water-insoluble/water dispersible protein fractioncan disperse a number of oils, depending upon the particular applicationit can be advantageous to isolate a more pure form of thewater-insoluble/water dispersible protein fraction. One approach forpreparing both water-soluble protein fractions and water-insoluble/waterdispersible protein fractions are shown schematically in FIG. 1.

As shown in FIG. 1, the starting material (for example, ground meal) isdispersed in aqueous media (for example, water) at pH 6.5-13 for atleast 5 minutes, at least 20 minutes, at least 40 minutes or at least 1hour, to form a mixture. Starting materials include, without limitation,whey protein, canola meal, canola protein isolate, castor meal, castorprotein isolate, soy meal, or soy protein isolate, or a combinationthereof. Then, optionally, the pH of the mixture can be lowered by theaddition of acid (to provide a mixture with a pH in the range of, forexample, 4.0-5.0) to precipitate both a portion of water-solubleproteins and water-insoluble proteins. At this point, the water-solubleproteins can be separated from the precipitate by harvesting thesupernatant. It is understood, that in certain embodiments, thewater-soluble protein fraction can be harvested prior to the step oflowering the pH (see FIG. 1). In other words, the starting material isdispersed in aqueous media (for example, water) and the watersoluble-material (containing the water-soluble protein fraction) isseparated from the water-insoluble material using conventionalseparation techniques. Alternatively, the water-soluble protein can beharvested after the pH has been lowered or can be harvested from thewashes, for example, water washes, of the water-insoluble material (seeFIG. 1). It is understood that the water-soluble protein can be producedby combining two or more of the aqueous fractions harvested at differentsteps that contain the water-soluble protein.

The residual water-insoluble material (i.e., the precipitate) can beharvested. The harvested material then can be washed (under certaincircumstances, washed extensively) with water and the remainingwater-insoluble/water dispersible material is harvested.

The protein isolation procedures described above can be modified to usea water-alcohol mixture instead of just water. For example,water-soluble proteins may be isolated by washing plant or animalmaterial with a water-alcohol mixture, and simply harvesting theproteins that dissolve in the water-alcohol mixture. A variety ofalcohols are contemplated to be amenable to the isolation conditions. Incertain embodiments, the alcohol is an aliphatic alcohol, aromaticalcohol, or a polyol such as PPG-2000. In certain embodiments, the ratioof water to alcohol in the water-alcohol mixture is in the range of from10:1 to 5:1, from 5:1 to 2:1, from 2:1 to 1:2, from 1:2 to 1:5, or from1:5 to 1:10.

It is understood that the water-soluble protein fraction and/or thewater-insoluble/water-dispersible protein fraction can be used as is ordried and stored until use. Drying can be performed by techniques knownin the art, including spray drying, freeze drying, oven drying, vacuumdrying, or exposure to desiccating salts (such as phosphorous pentoxideor lithium chloride).

It is understood that the process can also include one or more enzymedigestion and/or chemical hydrolysis steps. Digestion can be facilitatedusing one or more enzymes, and hydrolysis can be facilitated using oneor more chemicals, for example, acid- or alkali-based hydrolysis. Forexample, the starting material (for example, the ground meal) can beexposed to enzymatic digestion before or after, or both before and afterthe incubation of the starting material in the alkaline aqueous media.Alternatively, or in addition, an enzymatic digestion step can beperformed on the material following addition of acid to provide amixture with a pH in the range of 4.0 to 5.0. Alternatively, or inaddition, the harvested water-soluble protein fraction and/or thewater-insoluble/water dispersible material after harvesting can beexposed to enzymatic digestion. Chemical hydrolysis, however, can occurwith or replace the enzymatic digestion steps noted above.

Under certain circumstances residual basic species and alkali metalspresent in chemically digested proteins are not compatible withpolyisocyanates and can cause trimerization of the isocyanate groups,leading to stability problems in the final polyisocyanate compositions.Enzymatic digestion, however, can be used to avoid or reduce isocyanatestability problems associated with some chemical hydrolysis steps.

It is understood that enzymes useful in the digestion of the proteinfractions include endo- or exo-protease of bacterial, fungal, animal orvegetable origin or a mixture of thereof. Useful enzymes include, forexample, a serine-, leucine-, lysine-, or arginine-specific protease.Exemplary enzymes include trypsin, chymotrypsins A, B and C, pepsin,rennin, microbial alkaline proteases, papain, ficin, bromelain,cathepsin B, collagenase, microbial neutral proteases, carboxypeptidasesA, B and C, camosinase, anserinase, V8 protease from Staphylococcusaureus and many more known in the art. Also combinations of theseproteases may be used.

Also commercially available enzyme preparations such as, for example,Alcalase®, Chymotrypsine 800s, Savinase®, Kannase®, Everlase®,Neutrase®, Flavourzyme® (all available from Novo Nordisk, Denmark),Protex 6.0L, Peptidase FP, Purafect®, Purastar OxAm®, Properase®(available from Genencor, USA), Corolase L10 (Rohm, Germany), Pepsin(Merck, Germany), papain, pancreatin, proleather N and Protease N(Amano, Japan), BLAP and BLAP variants available from Henkel, K-16-likeproteases available from KAO, or combinations thereof. The Table 1 belowdescribes the amino acid specificity of certain useful endonucleases.

TABLE 1 Nota- No Amino Acid tion Commercial Endopeptidase(s) 1 Alanine APronase ®; Neutrase ®: 2 Cysteine C Papain 3 Aspartic D Fromase ®; 4Glutamic E Alcalase ®; 5 Phenylalanine F Neutrase ®: Fromase ® 6 GlycineG Flavorzyme ®; Neutrase ®: 7 Histidine H Properase ®; 8 Isoleucine INeutrase ®: 9 Lysine K Alcalase ®; Trypsin; Properase ® 10 Leucine LAlcalase ®; Esperase ®; Neutrase ®: 11 Methionine M Alcalase ®;Neutrase ®: 12 Asparigine N Savinase ®; Flavourzyme ®; Duralase ®; 13Proline P Pronase ®; Neutrase ®: 14 Glutamine Q Alcalase ® 15 Arginine RTrypsin; Properase ®; 16 Serine S Savinase ®; Flavourzyme ®; Duralase ®;17 Threonine T Savinase ®; Flavourzyme ®; Duralase ®; 18 Valine VNeutrase ®: 19 Tryptophane W Neutrase ®: Fromase ® 20 Tyrosine YAlcalase ®; Esperase ®; Fromase ®

Depending upon the choice enzyme(s), enzymatic digestion usually isconducted under aqueous conditions at the appropriate pH conditions (forexample, depending upon the enzyme or enzyme mixture at neutral or atlow pH). In certain digestion systems, the digestion optimally occurs ata pH less than 9, or less than 8. For certain applications, the pH ofthe aqueous protein digestion system is in the range of 3-9, 4-8 or5-7.5. Once digestion has proceeded to the desired extent, the enzymaticreaction can be stopped, and the resulting product can optionally bewashed and then used as is or dried to form a powder.

The physical and chemical properties of the resulting water-solubleprotein fraction and the water-insoluble/water-dispersible proteinfraction are described in more detail below.

In certain embodiments, the proteins in the isolated protein fractionsare modified. Suitable processes for the modification or derivatizationof the polypeptide fractions are provided in the literature. The natureand extent of modification will depend in large part on the compositionof the starting material. The derivative can be produced, for example,by replacing at least a portion of primary amine groups of said isolatedprotein with hydroxyl groups, deaminating the protein, or replacing aportion of amide groups of the protein with carboxyl groups, etc. Inother embodiments, the isolated polypeptide compositions describedherein can be obtained by reacting the protein with protein modifyingagents, for example, nitrous oxide, nitrous acid, salts of nitrous acid,or a combination thereof.

A. Water-Soluble Polypeptide Composition Capable of Stabilizing aPolyurethane-Based Foam

The water-soluble protein fractions, for example, the water-solubleprotein fractions isolated pursuant to the protocol set forth in FIG. 1,are substantially or completely soluble in water.

The water-soluble protein fractions have one or more of the followingfeatures: (a) an amide-I absorption band between about 1633 cm⁻¹ and1680 cm⁻¹, as determined by solid state FTIR, (b) an amide-II bandbetween approximately 1522 cm⁻¹ and 1560 cm⁻¹, as determined by solidstate FTIR, (c) two prominent 1° amide N—H stretch absorption bandscentered at about 3200 cm⁻¹, and at about 3300 cm⁻¹ as determined bysolid state FTIR, (d) a prominent cluster of protonated nitrogen nucleidefined by ¹⁵N chemical shift boundaries at about 94 ppm and about 100ppm, and ¹H chemical shift boundaries at about 7.6 ppm and 8.1 ppm, asdetermined by solution state, two-dimensional proton-nitrogen coupledNMR, (e) an average molecular weight of between about 600 and about2,500 Daltons, for example, as determined by MALDI mass spectroscopy,and (f) an inability to stabilize an oil-in-water emulsion, wherein,when aqueous solution comprising 14 parts by weight of protein dissolvedor dispersed in 86 parts by weight if water is admixed with 14 parts byweight of polymeric diphenyl methane diisocyanate (PMDI), the aqueoussolution and the PMDI produce an unstable suspension thatmacroscopically phase separates under static conditions within fiveminutes after mixing; (g) the water-soluble polypeptide composition iscapable of stabilizing a polyurethane-based foam relative to apolyurethane-based foam created from the same starting compositionlacking the water-soluble protein composition; and (h) the water-solublepolypeptide composition is capable of reducing the density of apolyurethane-based foam by at least 5% (for example, at least 10%, 20%,30%, 40%, 50%, 60%, 70%, 80%, 90% or 100%) relative to apolyurethane-based foam created from the same starting composition butthat lacks the water-soluble polypeptide composition.

In certain embodiments, the water-soluble polypeptide compositionscontain a substantial amount of primary amines, carboxylic acids, aminesalts, and carboxylate salts relative to the water-insoluble/waterdispersible protein fraction. The water-soluble protein fractioncomprises a relatively high concentration of primary amines (at about3300 and 3200 cm⁻¹) relative to secondary amine (at about 3275 cm⁻¹) asseen in FIGS. 4, 6 and 9.

B. Water-Insoluble/Water Dispersible Polypeptide Composition

The water-insoluble/water dispersible polypeptide composition ischaracterized by several physical and chemical properties.

One important property of the water-insoluble/water dispersible proteinfraction is that it is capable of dispersing or emulsifying oil in wateror water in oil (see Example 3). The protein fraction that has theseproperties generally includes one or more of the following features: (a)an amide-I absorption band between about 1620 cm⁻¹ and 1632 cm⁻¹ and anamide-II band between approximately 1514 cm⁻¹ and 1521 cm⁻¹, asdetermined by solid state FTIR, (b) a prominent 2° amide N—H stretchabsorption band centered at about 3272 cm⁻¹, as determined by solidstate FTIR, (c) an average molecular weight of between about 600 andabout 2,500 Daltons, and (d) two protonated nitrogen clusters defined by¹⁵N chemical shift boundaries at about 86.2 ppm and about 87.3 ppm, and¹H chemical shift boundaries at about 7.14 ppm and 7.29 ppm for thefirst cluster, and ¹H chemical shift boundaries at about 6.66 ppm and6.81 ppm for the second cluster, as determined by solution state,two-dimensional proton-nitrogen coupled NMR.

In contrast to the water-soluble protein composition, thewater-insoluble/water dispersible fraction is capable of dispersing oremulsifying oil in water or water in oil to produce a homogeneousemulsion stable, by visual inspection, for least 5 minutes. In certainembodiments, the dispersion or emulsion exhibits substantially no phaseseparation by visual inspection for at least 10, 15, 20, 25, or 30minutes, or even 1, 2, 3, 4, 5, 6, 9, 12, 18, or 24 hours after mixingthe polypeptide composition with the oil. As shown in Example 3, thewater-insoluble/water dispersible fraction is capable of emulsifying ordispersing a wide selection of oils, including, for example, an organicpolyisocyanate (for example, PMDI) mineral oil, soybean oil, derivatizedsoybean oil, motor oil, castor oil, derivatized castor oil, dibutylphthalate, epoxidized soybean oil, corn oil, vegetable oil, caprylictriglyceride, Eucalyptus oil, and tributyl o-acetylcitrate. In anexemplary assay, 14 parts (by weight) of a protein sample of interest ismixed with 86 parts (by weight) of water and the resulting solution ordispersion is mixed with 14 parts (by weight) of oil, for example, PMDI.Under these conditions, the water-insoluble/water dispersible proteinfraction produces a dispersion or emulsion exhibits substantially nophase separation by visual inspection for at least 5 minutes aftermixing the polypeptide composition with the oil.

In certain embodiments, the water-insoluble/water dispersible fractionis substantially free of primary amines, carboxylic acids, amine salts,and carboxylate salts. The water-insoluble protein/water dispersibleprotein fraction has a higher fraction of secondary amines relative tothe water-soluble protein fraction (see, Example 1).

The water-insoluble/water dispersible protein fraction can act as asurfactant to an organic polyisocyanate (e.g., PMDI), loweringinterfacial tension to the point where the water insoluble organicpolyisocyante is readily emulsified with minimal energy input, creatingan oil-in-water emulsion. When the source material is soy protein, astable emulsion can be obtained using undigested substantially insoluble(fractionated) protein. In certain embodiments, a stable emulsion ofpolyisocyanate (e.g., PMDI) in water can be achieved when the isolatedfractionated polypeptide is comprised of a water-insoluble/waterdispersible fraction, either alone, or in combination with a watersoluble component. In its dry powdered form, the water-insoluble/waterdispersible polypeptide is also capable of dispersing within an oil suchas PMDI. Thus, in certain embodiments, the water-insoluble polypeptidecan be pre-dispersed in the isocyanate-based reactant in the absence ofwater.

In certain embodiments, the water-soluble and/or water-insolublepolypeptide fractions described herein, can have a weight averagemolecular weight of between about 500 and 25,000 Daltons. Usefulpolypeptide fractions can have a weight average molecular weight ofbetween about 600 and 2,500 Da., between about 700 and 2,300 Da.,between about 900 and 2,100 Da., between about 1,100 and 1,900 Da.,between about 1,300 and 1,700 Da., between about 1,000 and 1,300 Da.,between about 2,000 and 2,500 Da., or between about 1,000 and 2,500 Da.

The isolated polypeptide composition can be used to make foams, asdescribed herein, by combining them with a reactive prepolymer. Reactiveprepolymers can be selected from the group consisting of an organicpolyisocyanate; a reaction product between an organic polyisocyanate anda polypeptide, a polyol, an amine based polyol, an amine containingcompound, a hydroxy containing compound, awater-insoluble/water-dispersible polypeptide composition, awater-soluble polypeptide, or a combination thereof. It is understood,however, that foams do not necessarily have to be isocyanate-based.Optional foams can include any liquid, liquid solution, or liquidmixture that is capable of polymerizing or gelling to form a rigidstructure in the presence of a blowing agent. Liquid mixtures caninclude for example PVC plastisols; liquids can include polymerizablemonomers such as styrene and methymethacrylate; liquid solutions caninclude polymers dissolved in solvents such as polystyrene dissolved insupercritical CO₂ or toluene. Alternatively, or in addition, the liquidscan also comprise prepolymers such as epoxy containing compounds; areaction product between an epoxy containing compound and a polypeptide,a polyol, an amine based polyol, an amine containing compound, a hydroxycontaining compound, or a combination thereof; an organosilane; apolymer latex; a polyurethane; and a mixture thereof.

When making the foams, the isolated polypeptide composition, in certainembodiments, is capable of dispersing the reactive prepolymer in theaqueous medium to produce a stable dispersion or a stable emulsion. Thedispersion or emulsion exhibits substantially no phase separation byvisual inspection for at least 5 minutes after mixing the polypeptidecomposition with the reactive prepolymer. In certain embodiments, thedispersion or emulsion exhibits substantially no phase separation byvisual inspection for at least 10, 15, 20, 25, or 30 minutes, or even 1,2, 3, 4, 5, 6, 9, 12, 18, or 24 hours after mixing the polypeptidecomposition with the reactive prepolymer. In certain embodiments, thedispersion or emulsion exhibits substantially no phase separation byvisual inspection for at least 10, 15, 20, 25, or 30 minutes, or even 1,2, 3, 4, 5, 6, 9, 12, 18, or 24 hours after mixing the polypeptidecomposition with the oil. As shown in Example 3, thewater-insoluble/water dispersible fraction is capable of emulsifying ordispersing a wide selection of oils, including, for example, an organicpolyisocyanate (for example, PMDI) mineral oil, soybean oil, derivatizedsoybean oil, motor oil, castor oil, derivatized castor oil, dibutylphthalate, epoxidized soybean oil, corn oil, vegetable oil, caprylictriglyceride, Eucalyptus oil, and tributyl o-acetylcitrate. In anexemplary assay, 14 parts (by weight) of a protein sample of interest ismixed with 86 parts (by weight) of water and the resulting solution ordispersion is mixed with 14 parts (by weight) of oil, for example, PMDI.Under these conditions, the water-insoluble/water dispersible proteinfraction produces a dispersion or emulsion exhibits substantially nophase separation by visual inspection for at least 5 minutes aftermixing the polypeptide composition with the oil.

In certain embodiments, the water-insoluble/water dispersible proteinfraction provides a stable emulsion or dispersion, for example, anaqueous emulsion or dispersion, comprising from about 1% to about 90%(w/w) of an oil and from about 1% to about 99% (w/w) of an isolatedpolypeptide composition, wherein the isolated polypeptide compositionproduces a stable emulsion or dispersion of the oil in an aqueousmedium. The aqueous emulsion or dispersion optionally comprises fromabout 1% to about 50% (w/w) of oil and from about 1% to about 99% (w/w)of the isolated polypeptide composition. The term “stable” when used inreference to the dispersions and emulsions refers to the ability of thepolypeptide fraction described herein to create a kinetically stableemulsion for the duration of the intended application of the dispersionor emulsion. The terms “emulsion,” “dispersion” and “suspension” areused interchangeable herein.

II. Isocyanate-Based Reactant

The term “isocyanate-based reactant,” as used herein, is understood tomean a compound that comprises an isocyanate group. A wide variety ofisocyanate-containing compounds are known in the art relating topreparation of polyurethane foams, and such compounds are contemplatedto be useful in the practice of the present invention.

In certain embodiments, the isocyanate-based reactant comprises aurethane, allophanate, urea, biuret, carbodiimide, uetonimine,isocyanurate or a combination. When the isocyanate based reactantcontains a urethane, these can be produced by reaction of an organicisocyanate with a polyol or other hydroxyl compound.

In certain embodiments, the isocyanate-based reactant is an organicpolyisocyanate. The term “polyisocyanate,” as used herein, refers todifunctional isocyanate species, higher functionality isocyanatespecies, and mixtures thereof. Depending on the circumstances, thereactive polyisocyanate is combined with the isolated and fractionatedpolypeptide described herein in order to form the compositions providedherein. Alternatively, the isocyanate-based reactant can be a productformed by reacting an organic polyisocyanate and a compound containing anucleophilic functional group capable of reaction with an isocyanategroup. Exemplary compounds containing a nucleophilic functional groupcapable of reacting with an isocyanate group include a polypeptide, apolyol, an amine based polyol, an amine containing compound, a hydroxycontaining compound, or a combination thereof. In certain otherembodiments, allophanate prepolymers are utilized. Allophanateprepolymers typically require higher temperatures (or allophanatecatalysts) to facilitate reaction of a polyol with the polyisocyanate toform the allophanate prepolymer.

As noted above, the organic polyisocyanate can be prepared from a “basepolyisocyanate.” The term “base isocyanate” as used herein refers to amonomeric or polymeric compound containing at least two isocyanategroups. The particular compound used as the base polyisocyanate can beselected so as to provide a foam having certain desired properties. Forexample, base polyisocyanate can be selected based on the number-averageisocyanate functionality of the compound. For example, in certainembodiments, the base polyisocyanate can have a number-averageisocyanate functionality of 2.0 or greater, or greater than 2.1, 2.3 or2.4. In certain embodiments, the reactive group functionality of thepolyisocyanate component ranges from greater than 1 to several hundred,2 to 20, or 2 to 10. In certain other embodiments, the reactive groupfunctionality of the polyisocyanate component is at least 1.9. Incertain other embodiments, the reactive group functionality of thepolyisocyanate component is about 2. Typical commercial polyisocyanates(having an isocyanate group functionality in the range of 2 to 3) may bepure compounds, mixtures of pure compounds, oligomeric mixtures (animportant example being polymeric MDI), and mixtures of these.

Useful base polyisocyanates have, in one embodiment, a number averagemolecular weight of from about 100 to about 5,000 g/mol, from about 120to about 1,800 g/mol, from about 150 to about 1,000 g/mol, from about170 to about 700 g/mol, from about 180 to about 500 g/mol, or from about200 to about 400 g/mol. In certain other embodiments, at least 80 molepercent or, greater than 95 mole percent of the isocyanate groups of thebase polyisocyanate composition are bonded directly to an aromaticgroup. In certain embodiments, the foams described herein have aconcentration of free organically bound isocyanate (—NCO) groups in therange of from about 5% to 35% (wt/wt), about 7% to 31% (wt/wt), 10% to25% (wt/wt), 10% to 20% (wt/wt), 15% to 27% (wt/wt).

In certain embodiments, the base polyisocyanate is an aromaticpolyisocyanate, such as p-phenylene diisocyanate; m-phenylenediisocyanate; 2,4-toluene diisocyanate; 2,6-toluene diisocyanate;naphthalene diisocyanates; dianisidine diisocyanate; polymethylenepolyphenyl polyisocyanates; 2,4′-diphenylmethane diisocyanate(2,4′-MDI); 4,4′-diphenylmethane diisocyanate (4,4′-MDI);2,2′-diphenylmethane diisocyanate (2,2′-MDI);3,3′-dimethyl-4,4′-biphenylenediisocyanate; mixtures of these; and thelike. In certain embodiments, polymethylene polyphenyl polyisocyanates(MDI series polyisocyanates) having a number averaged functionalitygreater than 2 are utilized as the base polyisocyanate.

In certain embodiments, the MDI base polyisocyanate comprises a combined2,4′-MDI and 2,2′-MDI content of less than 18.0%, less than 15.0%, lessthan 10.0%, or less than 5.0%.

In certain other embodiments, the MDI diisocyanate isomers, mixtures ofthese isomers with tri- and higher functionality polymethylenepolyphenyl polyisocyanates, the tri- or higher functionalitypolymethylene polyphenyl polyisocyanates themselves, and non-prepolymerderivatives of MDI series polyisocyanates (such as the carbodiimide,uretonimine, and/or isocyanurate modified derivatives) are utilized aspolyisocyanates for use as the base polyisocyanate. In certain otherembodiments, the base polyisocyanate composition comprises an aliphaticpolyisocyanate (e.g., in a minor amount), e.g., an aliphaticpolyisocyanate comprising an isophorone diisocyanate, 1,6-hexamethylenediisocyanate, 1,4-cyclohexyl diisocyanate, or saturated analogues of theabove-mentioned aromatic polyisocyanates, or mixtures thereof.

In certain other embodiments, the base polyisocyanate comprises apolymeric polyisocyanate, e.g., a polymeric diphenylmethane diisocyanate(polymethylene polyphenyl polyisocyanate) species of functionality 3, 4,5, or greater. In certain embodiments, the polymeric polyisocyanates ofthe MDI series comprise RUBINATE-M® polyisocyanate, or a mixture of MDIdiisocyanate isomers and higher functionality oligomers of the MDIseries. In certain embodiments, the base polyisocyanate product has afree —NCO content of about 31.5% by weight and a number averagedfunctionality of about 2.7.

In certain embodiments, the isocyanate group terminated prepolymers areurethane prepolymers. These can be produced by reaction of ahydroxyl-functional compound with an isocyanate functional compound. Incertain other embodiments, allophanate prepolymers are utilized.Allophanate prepolymers typically require higher temperatures (orallophanate catalysts) to facilitate reaction of the polyol with thepolyisocyanate to form the allophanate prepolymer.

Polyisocyanates used in the compositions described can have the formulaR(NCO)_(n). where n is 2 and R can be an aromatic, a cycloaliphatic, analiphatic, each having from 2 to about 20 carbon atoms. Examples ofpolyisocyanates include, but are not limited to,diphenylmethane-4,4′-diisoeyanate (MDI), toluene-2,4-diisocyanate (TDI),toluene-2,6-diisocyanate (TDI). methylene bis(4-cyclohexylisocyanate(Hi₂MDI), 3-isocyanatomethyl-3,5,5-trimethyl-cyclohexyl isocyanate(ÏPDI), 1,6-hexane diisocyanate (HDl), naphthalene-1,5-diisocyanate(NDI), 1,3- and 1,4-phenylenediisocyanate,triphenylmethane-4,4′,4″-triisocyanatc, polymeric diphenylmethanediisocyanate (PMDI), m-xylene diisocyanate (XDI), 1,4-cyclohexyldiisocyanate (CHDl), isophorone diisocyanate, isomers, dimers, trimersand mixtures or combinations of two or more thereof. The term “PMDI”encompasses PMDI mixtures in which monomeric MDI, for example 4,4′-,2,2′- and/or 2,4′-MDI, is present. PMDI is, in one embodiment, preparedby phosgenation of the corresponding PMDA in the presence of an inertorganic solvent. PMDA is in turn obtained by means of an acidaniline-formaldehyde condensation which can be carried out industriallyeither continuously or batchwise. The proportions ofdiphenylmethanediamines and the homologouspolyphenylpolymethylenepolyamines and their positional isomerism in thePMDA are controlled by selection of the ratios of aniline, formaldehydeand acid catalyst and also by means of a suitable temperature andresidence time profile. High contents of 4,4′-diphenylmethanediaminetogether with a simultaneously low proportion of the 2,4′ isomer ofdiphenylmethanediamine are obtained on an industrial scale by the use ofstrong mineral acids such as hydrochloric acid as catalyst in theaniline-formaldehyde condensation.

The level of covalent cross-linking, which impacts the rigidity of thefoam, can be influenced by the reactive group functionality of themonomers. Reactive group functionalities discussed herein will beunderstood to be number averaged for polymeric or oligomeric materials(such as polymeric polyols, polyisocyanate prepolymers,uretonimine-carbodiimide modified polyisocyanates, and the polymericisocyanates of the MDI series) and absolute for pure compounds. Thereactive group functionality of the polyisocyanate component ranges fromgreater than 1 to several hundred, 2 to 20, or 2 to 10. In certainembodiments, the polyisocyanate functionality is at least 1.9, or atleast 2.0.

Polyisocyanates, which are commercially available, can be purecompounds, mixtures of pure compounds, oligomeric mixtures (an importantexample being polymeric MDI), and mixtures of the foregoing. The rangeof isocyanate group functionalities for the commercial polyisocyanatesis understood in the art to be from 2 to 3. The higher the reactivegroup functionalities of the monomers used in the foam formulation, thehigher the crosslink density will be. Very highly crosslinkedpolyurethane foams tend to be rigid (hard).

The extent of cross-linking is not the only factor that determines therigidity (or flexibility) of a cellular polyurethane. The backbonerigidity of the matrix polymer, which is determined by the rigidity ofthe precursor monomers, can also affect rigidity of the foam. Monomershaving a highly rigid backbone can produce rigid foams which are notcross-linked, or only lightly cross-linked. Examples of relatively rigidmonomers include those having a high concentration of aromatic rings.The combination of an aromatic polyisocyanate and an aromatic polyoltends to produce a polymer with a rigid backbone, hence the polymertends to be rigid and foams made from it are rigid.

The flexibility of a polymer is also affected by secondary inter-chainforces such as hydrogen bonding and crystallinity. Since polyurethanesand polyureas formed from the reaction of polyisocyanates andpolyfunctional active hydrogen monomers tend to have high concentrationsof “—NH” groups along the polymer backbone, they are often hydrogenbonded. The equivalent weights of the monomers determines the number of“—NH” groups along the polymer backbone. As a result, the use ofmonomers of lower functional group equivalents weight produces a polymerhaving more “—NH” groups in its structure. These, therefore, tend tohave more hydrogen bonds between the chains, and thus are often morerigid. With all other factors being equal, the use of monomers of higherequivalent weights tends to reduce the amount of hydrogen bondingbetween the polymer chains, producing a more flexible polymer. Ureagroups tend to produce more hydrogen bond linkages than urethane groups,such that a high urea concentration in the polymer structure tends toresult in a more rigid material than one with only urethane groups.

The ability of the polymer backbone to form crystalline, ormicrocrystalline, domains in the bulk material can also have asignificant impact on the rigidity of the material. This ability issometimes realized in polyurethanes having very regular repeatingstructures, and these materials can be highly rigid. However,crystallinity can easily be disrupted by covalent crosslinks and otherirregularities in the backbone structure. This is an example of a casewhere one factor (e.g., crystallinity) may conflict with another factor(e.g., cross-linking) It is understood that the effects of the differentfactors controlling the degree of foam rigidity are not always additivebut can be adjusted to give foams of desired properties using techniquesknown to those skilled in the art.

III. Isocyanate-Reactive Compound

The term “isocyanate-reactive compound,” as used herein, refers to acompound containing a chemical functionality reactive with an isocyanategroup. A variety of isocyanate-reactive compounds are known in the art,and are contemplated to be useful in the practice of the presentinvention. Selection of particular isocyanate-reactive compounds and therelative amounts of such compounds used in the foam-forming compositioncan be performed to provide foams having desired chemical and physicalfeatures.

A. Types of Isocyanate-Reactive Compounds

Isocyanate-reactive compounds typically are nucleophilically reactivewith an isocyanate-based reactant. Isocyanate-reactive compounds usefulin making polyurethane foams can be organic compounds containing aplurality of active hydrogen groups capable of forming a polymer byreaction with the isocyanate. Reactive functional groups contemplated tobe amenable to the present invention include, for example, primaryalcohols, secondary alcohols, polyols, primary amines, secondary amines,and carboxylic acids. Exemplary primary alcohols and secondary alcoholsinclude aliphatic alcohols, whereas primary amines and secondary aminesinclude aromatic amines and aliphatic amines. Furthermore, theisocyanate-reactive compound can include a water-insoluble/waterdispersible protein composition and/or water-soluble proteincomposition, used either alone or in combination with any of theforegoing isocyanate-reactive compounds.

The choice of a given isocyanate-reactive compound can impact theproperties of the resulting foam. For example, a distinguishing featureof flexible polyurethanes foams is the use of a high concentration byweight (relative to the total formulation weight) of at least oneflexible polyol. Flexible polyols can comprise, for example, from about25% to about 90% (wt/wt) or from about 50% to about 70% (wt/wt) of thefoam composition and contribute to the flexible nature of these foams.The flexible polyols are themselves polymeric materials, usually liquidsor low melting solids, containing hydroxyl groups at the chain termini.Exemplary flexible polyols have molecular weights in the range of 1,500to 12,000 g/mol or 2,000 to 8,000 g/mol and have nominal —OHfunctionalities of 2 to 4, usually 2 to 3. The flexible polyols, as thename implies, have flexible backbones and are predominantly aliphatic.The flexible backbone is a polymer with a low glass transitiontemperature (e.g., less than 0° C., or less than −10° C.). Furthermore,it is desirable for the compound to be a liquid at ambient temperatures.Such flexible polyols can be classified by backbone polymer type intothree categories: polyethers, polyesters, and hydrocarbons. Although oneof the three basic backbone types can be used in a polyol, it iscontemplated that certain polyols contain two or three of these basicbackbone types. Furthermore, mixtures of different types of flexiblepolyols may be used to prepare the foam. Non limiting examples ofhydrocarbon backbone types include the polybutadienes and thepolyisoprenes, and the hydrogenated derivatives thereof. Copolymers ofbutadiene and isoprene, and hydrogenates of these copolymers can also beused. Non limiting examples of polyether backbone types includepolyoxypropylene, polyoxyethylene, polytetramethylene, polyoxybutylene,and any of the possible copolymers thereof. Preferred polyether backbonetypes include polyoxypropylenes, polyoxyethylenes,polyoxypropylene-polyoxyethylene copolymers, and thepolytetramethylenes.

In certain embodiments, the isocyanate-reactive compound is apolyoxyethyene capped polyoxypropylene polyol, which is predominantlyprimary —OH terminated.

Polyether polyols are most commonly made by polymerizing one or morealkylene oxides (such as ethylene oxide, propylene oxide, butyleneoxide, or tetramethylene oxide) with a low molecular weight initiatormolecule (such as water, ammonia, a glycol, a triol, or an amine; ofmolecular weight less than 150) in the presence of a catalyst. Mixturesof initiators can be used in the synthesis.

A widely used class of polyether polyols are polyoxyethylene cappedpolyoxypropylene diols and triols comprising predominantly propyleneoxide by weight. Other widely used classes of polyether polyols are thepolyoxypropylene diols and triols. The polyoxypropylene polyols areimportant in continuously produced slabstock flexible foam. Thepolyoxyethylene capped polyoxypropylene polyols are important in moldedflexible foam applications. These polyoxyethylene capped polyols areparticularly well suited to cold curing, due to the presence of primary—OH groups as the predominant isocyanate-reactive functional groups.Non-limiting examples of polyester type flexible polyols include thoseformed from the condensation of low molecular weight aliphatic diols ofmolecular weight less than 150 with aliphatic dicarboxylic acids ofmolecular weight less than 300, under conditions that promote hydroxyltermination. Preferred aliphatic diols for making these polyesters arethe diprimary diols. Some specific examples of polyester diols are thepoly(ethylene adipates), poly(butylene adipates), poly(diethylene glycoladipates), and the copolymers of these. These aliphatic polyesterssometimes additionally contain very minor amounts of triols, such astrimethylolpropane, to increase the hydroxyl functionality. Polyethertype flexible polyols derived from propylene oxide and/or ethylene oxideare especially preferred because of their low cost.

Polyols useful in preparing the foams described herein include all knownpolyols, for example, polyols used in the polyurethanes art. In certainembodiments, the polyol comprises primary and/or secondary hydroxyl(i.e., —OH) groups. In certain other embodiments, the polyol comprisesat least two primary and/or secondary hydroxyl groups per molecule. Monofunctional alcohols (such as aliphatic alcohols, aromatic alcohols orhydroxyl functional monomers such as hydroxyl functional acrylates (toyield UV or thermally curable materials)) can be used to cap anisocyanate group. In certain other embodiments, the polyol comprises ahydroxyl group functionality from 1.6 to 10, from 1.7 to 6, between 2 to4, or from 2 to 3. In certain other embodiments, the weight averagemolecular weight range for the optional polyols is from 100 to 10,000g/mol, from 400 to 6,000 g/mol, or from 800 to 6,000 g/mol.

In certain other embodiments, useful polyols are polyester polyols orpolyether polyols, such as an aliphatic polyether polyol. One exemplaryaliphatic polyether polyol is polyoxypropylene glycol, with a numberaverage molecular weight in the range of from 1,500 to 2,500 g/mol.

In certain embodiments, the total amount of all polyol, or polyols, inthe isocyanate reactive component is from 1% to 80%, or from 3% to 70%,or from 5% to 60% by weight of the total.

In certain other embodiments, alkanolamines comprising primary,secondary, and/or tertiary amine groups can be used.

B. Amount of Isocyanate-Reactive Compound Used to Form the Foam

The relative amounts of the ingredients used to form the foam can impactthe chemical and physical properties of the foam. For example, the ratioof the number of isocyanate groups in the isocyanate-based reactants tothe total number of isocyanate-reactive groups (i.e., the total numberof isocyanate-reactive functional groups that would be expected to reactunder the conditions of processing, including those contributed by theblowing agent) is a important parameter. The ratio of reactiveequivalents (isocyanate:isocyanate reactive groups) is called the Index,and can be expressed as a percent.

Preparation of foam from material having an Index less than 100% canimply reduced cross-linking due to the presence of unreacted chain ends,thereby reducing the average density of cross-linking. However, oneexception is when water (a blowing agent) is included in large excess.In this situation, some of the water molecules behave as a physicalblowing agent (if the heat of the foaming reaction is sufficient tovolatilize it during the foaming process). Otherwise, a large excess ofwater simply remains in the foam (eventually drying out) and need notsubstantially increase the number of unreactive polymer chain ends.

Preparation of foam from material having an Index above 100% can implyadditional cross-linking Additional cross-linking comes from variousself-reactions of isocyanate groups (—NCO groups) as well as theformation of allophanate and biuret groups. Exemplary self-reactions ofisocyanate groups in foam processing include carbodiimide formation,uretonimine formation, and isocyanurate formation (trimerization). Someof these self-reaction products can optionally also be present in theliquid polyisocyanate precursor stream (base polyisocyanate), but onlythe free isocyanate groups which remain are considered when calculatingthe Index of a urethane foam formulation. If, for example, a largeexcess of isocyanate (—NCO) groups is present in the formulation(corresponding to an Index of greater than 150%) and a catalyst for thetrimerization of isocyanate groups (trimerization catalyst) is present,then the foam will contain significant quantities of isocyanuratelinkages. The isocyanurate linkages increase the crosslink densitysubstantially. These linkages are heat resistant and often areincorporated into rigid foams in order to increase combustionresistance.

The Index of a foam formulation is an important indicator of howflexible or rigid the foam will be. More covalent cross-linking (higherIndex) generally means greater rigidity. Index ranges of from 10% orless (in extreme cases, where water is used in very large excess) up to150%, or from 70% to 125%, can be used to prepare flexible urethanefoams. A desirable Index range for most flexible thermoset urethanefoams is from 80% to 110%. This is also the Index range most preferredfor semi-rigid and semi-flexible foams. The terms semi-rigid andsemi-flexible are used interchangeably.

Index ranges of from 200% to 2,500%, from 250% to 1,500%, or from 250%to 800% can be used to prepare polyurethane-polyisocyanurate foams.These foams are an important subclass of rigid urethane foams used asinsulation foams in the construction industry. However, ifpolyisocyanurate linkages are not desired, then the Index range can bein the range of from 90% to 150%, or from 100% to 125%.

Reactive group functionalities for the organic isocyanate-reactive(active hydrogen) monomers suitable for use in the isocyanate-reactivecomponent(s) of a foam formulation range from greater than 1 to severalhundred, but much more generally from 1.5 to 20, more generally from 1.6to 10. Having a functionality of more than 1.0 is important for chainextension (growth/polymerization) because there is more than one groupto react with. If the functionality was 1.0, like a mono-alcohol, theisocyanate would become endcapped and the reaction would stop becausethe molecule has no more reactive groups.

In certain embodiments, the reactive group functionality for all thepolymer-forming isocyanate-reactive species used in the formulation beat least 1.5, and ideally at least 2. However, an industrially importantclass of useful isocyanate reactive monomers have functionalities in therange from 1.5 to 2. These are the polyoxyalkylene diols (whichnominally are diols) but actually have a hydroxyl functionality lessthan 2.

IV. Blowing Agents

Under certain circumstances, an additional blowing agent can be includedin a premix to facilitate foam formation. The blowing agent producesbubbles (cells) in the polymer giving rise to the foam product. A largenumber of blowing agents are known in the art and are contemplated to beuseful in the practice of the present invention. For example, theblowing agent can be physical blowing agent, which is a volatilecomposition that is a gas or converts to a gas under the conditions usedto prepare the form. Alternatively, the blowing agent (e.g., CO₂) can beformed in situ during preparation of the foam by adding a compound(e.g., water) to the premix that reacts with one of the components ofthe premix to form a blowing agent. Blowing agents of this type arechemical blowing agents. A further class of blowing agents are thosethat decomposes during the foam-forming process to liberate a gas (forexample, azo-functional compounds such as azobisdicarbonamide).

Commonly used physical blowing agents include air, nitrogen, and carbondioxide, which are whipped into the liquid chemical precursors of thepolyurethane foam. This method can be used to prepare high densityfoams. However, this procedure can be suboptimal for preparing lowdensity foams. Other commonly used physical blowing agents includevolatile inert organic compounds having boiling points (at 1 atmospherepressure) from 0 to 50° C., from 10 to 40° C., or from 20 to 35° C. Incertain instances, the organic physical blowing agent is a C₁-C₅hydrocarbon C₁-C₅ fluorocarbons, C₁-C₅ hydrofluorocarbon, C₁-C₅chlorocarbon, or a combination thereof. Non-limiting examples of suchphysical blowing agents include tetrafluoroethanes, pentafluoropropanes,methylene chloride, n-pentane, isopentane, and cyclopentane.

A common chemical blowing agent is water, where water reacts with twoequivalents of organic isocyanate groups to liberate a mole of carbondioxide (per water molecule) and form a urea linkage. Less commonly usedchemical blowing agents include carboxylic acid compounds, which canreact with isocyanates to liberate carbon dioxide and form an amidelinkage.

The quantity of the blowing agent(s) used in the foam-formingformulation can be adjusted to produce the foam having the desireddensity. The density range for cellular polyurethanes ranges from as lowas 0.1 lbs per cubic foot up to any amount short of full density (fulldensity being the natural density of the polymer, without any expansion(i.e., no bubbles)). The amount of blowing agent(s) needed to produce afoam of a particular density from a given foam formulation is understoodby those skilled in the art. When used, water is used in amounts from0.1 to as much as 100% by weight or more of the reactive polymer formingmonomers, but more typically from 0.2% to 20%. When used, physicalblowing agents are used in amounts from 1% to 50% by weight of thereactive (polymer forming) monomers, but more typically from 2% to 30%.

V. Additives

In addition, additives can be added to the foam-forming premix in orderto optimize the properties of the foam. Exemplary additives includecatalysts, extenders, fillers, surfactants, viscosifying agents,antioxidants, antibacterial agents, fungicides, pigments, inorganicparticulates, and cross-linking agents.

In certain embodiments, the catalyst(s) can comprise up to about 5% byweight of the foam-forming composition. Commonly used catalysts includetertiary amines and certain organometallic compounds. For example, thecatalyst can be triethylenediamine, 2,2′-dimethylamino diethyl ether,2-dimethylamino ethanol, stannous octoate, dibutyltin diacetate,dibutyltin dilaurate, or a combination thereof. These catalysts drivethe reaction of isocyanates with alcohols and with water. Othercatalysts drive the trimerization of isocyanate groups to formisocyanurate groups. Examples of these include potassium octoate(potassium 2-ethyl hexanoate), potassium acetate, and other alkali metalsalts of soluble carboxylic acids. Additional catalysts contemplated tobe amenable to preparing the foams described herein are described below.

Additional exemplary catalysts include a primary amine, a secondaryamine, a tertiary amine, an organometallic compound, or a combinationthereof. Exemplary primary amines include, for example, methylamine,ethylamine, propylamine, cyclohexylamine, and benzylamine. Exemplarysecondary amines include, for example, dimethylamine, diethylamine, anddiisopropylamine. Exemplary tertiary amines include, for example,diazabicyclooctane (Dabco), triethylamine, dimethyl benzylamine,bis-dimethylaminoethyl ether, tetramethyl guanidine,bis-dimethylaminomethyl phenol, 2,2′-dimorpholinodiethyl ether,2-(2-dimethylaminoethoxy)-ethanol,2-dimethylaminoethyl-3-dimethylaminopropyl ether,bis-(2-diaminoethyl)-ether, N,N-dimethyl piperazine,N-(2-hydroxyethoxyethyl)-2-azanorbornane, Tacat DP-914 (TexacoChemical), Jeffcat®, N,N,N,N-tetramethyl butane-1,3-diamine,N,N,N,N-tetramethyl propane-1,3-diamine, N,N,N,N-tetramethylhexane-1,6-diamine, 2,2′-dimorpholinodiethyl ether (DMDEE), or a mixturethereof. Exemplary organometallic compounds include, for example,di-n-octyl tin mercaptide, dibutyl tin maleate, diacetate, dilaurate,dichloride, bis-dodecyl mercaptide, tin(II)acetate, ethyl hexoate anddiethyl hexoate, Fe⁺³ 2,4-pentanedionate (FeAcAc), or lead phenyl ethyldithiocarbamate.

Exemplary extenders include, for example, inert extenders or activeextenders. In certain embodiments, the inert extender is vegetableparticulate matter, vegetable oil, mineral oil, dibasic esters,propylene carbonate, non-reactive modified aromatic petroleumhydrocarbons, and in general any non-active hydrogen containing liquidthat can be incorporated into the foam. The active extender can be apyrrolidone monomer or polymers, an oxizolidone monomer or polymers, anepoxidized oil, or an unsaturated oil, such as linseed oil.

In addition, one or more surfactants can be added to the foam-formingcomposition to alter the chemical and physical properties of the foam.In certain embodiments, the surfactant(s) can comprises up to about 5%by weight of the foam-forming composition. Exemplary surfactantsinclude, for example, monomeric types, polymeric types, or mixturesthereof. One commonly used surfactant is an organofunctional siliconecompound, such as a polyether silicone. Combinations of differentsilicones can be selected to balance foam stability during rise with theneed to open the cells (in open celled foams).

Other additives include, for example, antioxidants, antifoaming agents,anti-bacterial agents, fungicides, pigments, viscosifying agents,gelling agents, aereosolozing agents, inorganic particulates (e.g.,titanium dioxide, yellow iron oxide, red iron oxide, black iron oxide,zinc oxide, aluminum oxide, aluminum trihydrate, calcium carbonate),clays such as montmorillonite, wetting agents, and the like.

In certain embodiments, the additive is a water-dispersible additive ora water-soluble additive. Water-soluble additives includehydroxyl-functional or amine-functional compounds (such as glycerin,urea, propylene glycol, polypropylene glycol, polyethylene glycol,trimethylol propane and its adducts, etc.) capable of reacting with apolymeric isocyanate, e.g., PMDI.

In other embodiments, the additive can be a cross-linking agent, forexample, a cross-linking agent that can be used to bond lignocellulosicmaterial to glass. Exemplary cross-linking agents include anorganosilane, such as dimethyldichlorosilane (DMDCS),alkyltrichlorosilane, methyltrichlorosilane (MTCS),N-(2-aminoethyl)-3-aminopropyl trimethoxysilane (AAPS), or a combinationthereof. In other embodiments the polypeptide fractions are combinedwith an organosilane. The term “organosilane” refers to any group ofmolecules including monomers, hydrolyzed monomers, hydrolyzed dimers,oligomers, and condensation products of a trialkoxysilane having ageneral formula:

(RO)₃Si—R′

where R is preferably a propyl, ethyl, methyl, isopropyl, butyl,isobutyl, sec-butyl, t-butyl, or acetyl group, and R′ is anorganofunctional group where the functionality may include anaminopropyl group, an aminoethylaminopropyl group, an alkyl group, avinyl group, a phenyl group, a mercapto group, a styrylamino group, amethacryloxypropyl group, a glycidoxy group, an isocyante group, orothers.

Similarly, a bis-trialkoxysilane having the general formula(RO)₃Si—R′—Si(OR)₃ can also be employed as an “organosilane” eitheralone or in combination with a trialkoxysilane, where R is preferably apropyl, ethyl, methyl, isopropyl, butyl, isobutyl, sec-butyl, t-butyl,or acetyl group, and R′ is a bridging organofunctional residue which maycontain functionality selected from the group consisting of aminogroups, alky groups, vinyl groups, phenyl groups, mercapto groups, andothers. Similarly, a tetraalkoxysilane having the general formula(RO)₄Si can also be employed as an “organosilane” either alone or incombination with a trialkoxysilane, or a bis-trialkoxysilane, where R ispreferably a propyl, ethyl, methyl, isopropyl, butyl, isobutyl,sec-butyl, t-butyl, or acetyl group.

Other types of additives, which are of a more optional andapplication-specific nature, include fire retardants, fillers,reinforcements (such as glass fibers, mineral platelets such aswollastonite, and fibrous preforms), smoke suppressants, biocides, inertplasticizers, antistatic agents, combinations of these, and a host ofothers. The skilled artisan can select the appropriate amount of suchadditives based on the properties desired for the foam. For example,fillers can be used at very high levels, and can exceed the weight ofthe total polymer forming monomers in the formulation in somesituations. Fillers can include cheap particulates such as calciumcarbonate, clay minerals, sawdust and wood fibers. Fibrousreinforcements can also be use at levels exceeding the weight of thetotal polymer forming monomers in the formulation. Other types ofoptional additives, when used at all, are typically used at levels lessthan 15% or 10% by weight of the total polymer formulation. Most typesof optional additives are individually used at levels of less than 5% byweight of the total formulation.

Examples of fire retardants include organophosphorus compounds,halogenated organophosphorus compounds, halogenated aromatic compounds,melamine (as filler), graphite (filler), alumina trihydrate (filler),antimony oxide, and combinations of the foregoing. This list is not tobe construed as limiting. Soluble fire retardants are generallypreferred and can be effective at lower levels than filler type fireretardants.

The appropriate use of additives in the formulation of reaction systemsfor cellular polyurethanes will be understood by those skilled in theart. Some additives contain isocyanate reactive functional groups andtherefore must be accounted for in calculating the Index of foamformulations that contain these additives.

VI. Manufacture and Characteristics of Resulting Foams

The invention provides for the preparation of a variety of foamscharacterized by the different physical and chemical features. Forexample, the foam can be a thermoset foam or a thermoplastic foam.

A thermoset foam typically is prepared by reacting liquid precursors.Mixing the precursors (isocyanate-based reactant, isocyanate-reactiveagent, blowing agent, and polypeptide composition) initiates thepolymerization reaction and generates heat. The heat of reaction aids inthe foam expansion. Shaping of the final foam article takes place duringthe foaming and polymerization process, while the reaction mixture isstill flowable. In thermoset urethane foams the matrix polymer often iscross-linked. The extent of cross-linking depends on the stoichiometryof the polymer forming reaction and the reactive group functionalitiesof the monomers used. The amount of cross-linking can varysignificantly, and the amount of cross-linking can be adjusted tooptimize the properties of the foam. For example, rigid urethane foamsgenerally are more highly cross-linked than flexible urethane foam.

When making thermoset urethane foams, the isocyanate-reactiveingredients are usually combined with the blowing agent (especially ifthe blowing agent comprises isocyanate reactive functional groups, as inthe case of water) and optional additives to produce a liquid mixture.The liquid mixture then is mixed with a isocyanate-based reactant toinitiate polymerization and foaming. In some variations on this generalprocess, a portion of the isocyanate-reactive ingredients can optionallybe pre-reacted with a stoichiometric excess of a polyisocyanate to forma liquid isocyanate-terminated prepolymer. The prepolymer is laterreacted with the remainder of the isocyanate-reactive ingredients in thefinal step (to complete the polymerization and initiate foaming). In themost common variation on the prepolymer process, the prepolymer alsocomprises residual monomeric polyisocyanate species (basepolyisocyanates). These sometimes are referred to as semiprepolymers,pseudoprepolymers, or quasiprepolymers. These terms are usedinterchangeably. If the isocyanate terminated prepolymer contains nomonomeric polyisocyanate species it is referred to as a full prepolymer.Whether or not a prepolymer is used, the most common processing mode forthermosetting urethane foams is to use two liquid components (i.e., apolyisocyanate component, and the blend of isocyanate-reactive monomersplus blowing agents plus optional additives). There are however someimportant exceptions to this rule. During the continuous manufacture offlexible foam slabstock and rigid foam laminates, three or morecomponents are often used. The additional components may comprisereactive polymer-forming ingredients of the formulation (such aspolyisocyanates or polyols).

Thermoplastic foams often are prepared using a two-step procedure. Forexample, in certain embodiments, polymer forming ingredients areprocessed into solid pellets, which are compounded with any desiredadditives and blowing agents. The final forming and expanding operationis accomplished by applying external heat, usually in an extruder. Theexternal heat drives the expanding process by volatilizing a volatileblowing agent, by decomposing a chemical blowing agent to liberate agas, or some combination of these processes. The thermoplastic foam isshaped in a molding means, and the shape is locked in when the matrixpolymer cools and solidifies. Thermoplastic urethane foams are usuallylinear, although limited cross-linking may occur during the formingprocess.

The foam-forming materials described herein can be used to prepareflexible foam, rigid foam, or semi-rigid foam. Flexible foams made frompolyurethanes, for example, often have polymer matrices that are phaseseparated elastomers. The flexible phase of the polymer is the portionderived from the flexible polyol. Since this flexible phase is often thepredominant portion of the polymer by weight, it is a continuous phase.The non-flexible portion of the polymer is that derived from thereaction of polyisocyanates with water and (optionally) low molecularweight glycols of less than 200 molecular weight. This “hard” phase ofthe polymer typically separates from the soft phase duringpolymerization. Although the “phases” are covalently bonded to eachother, they behave as if separate. Hence, the matrix polymer iselastomeric, but its hardness is determined by the relative proportionsof the hard and soft phases. These relative proportions are adjustable,by selecting how much flexible polyol is used as a percentage of thetotal formulation.

Flexible foam formulations typically are blown mostly or exclusivelywith water (sometimes augmented with air or carbon dioxide injected intothe liquid chemical precursor streams). Preparation of lower densityfoam typically requires more water (to generate CO₂ for expansion),which produces more urea groups in the hard phase, thus higher hardnessof the foam. Minor amounts of low molecular weight glycols (of molecularweight less than 200, preferably less than 150) are sometimes includedin the formulation if a hard and resilient flexible foam is desired.These glycols typically are less than 10% of the total formulation,desirably less than 5%, and sometimes are referred to as chainextenders. The preferred glycols are linear di-primary diols such asethylene glycol, 1,4-butanediol, 1,6-hexanediol, and combinations ofthese. Foams of this type are called “high resilience” (or HR) foams.Flexible foams typically have densities less than 5 lbs per cubic foot,more typically less than 3 lbs per cubic foot, and are predominantlyopen celled.

Flexible foams of very low density (less than 1 lb per cubic foot) canbe prepared by crushing rigid foams that contain minor amounts offlexible polyols in their matrix polymer phase. The crushing has theeffect of breaking the rigid rod-like segments that form the boundariesbetween the cells of the foam (referred to as “struts”). Such flexiblefoams can be used as cushioning materials in automotive seating,furniture, and bedding. Foam densities for these applications range fromabout 1.5 to 4 lbs per cubic foot, more typically 1.8 to 3 lbs per cubicfoot.

Flexible foams usually are open celled foams, except at very highdensities (over 4 lbs per cubic foot). Because of their open celledstructure, water blowing is the preferred mode of foam expansion.Flexible foams usually are made with a flexible polymer matrix. Thecrosslink density in the polymer matrix is low and the Index is seldomhigher than 105% (often lower than 100%). The number averagedfunctionality of the polyisocyanates used in flexible foams are low,usually from 2 to 2.4, more typically from 2 to 2.3.

Rigid foams typically have a rigid plastic matrix. The matrix polymertypically is either a polyurethane or a polyurethane-polyisocyanurate.In either case, the polyols used are quite different from the types usedin flexible foams. The rigid polyols overlap to some degree withflexible polyols in molecular weight, typically ranging from 400 to2,000, more commonly 500 to 1,500. The rigid polyols may be grouped intotwo broad categories. The first are rigid backbone, low functionalityaromatic polyesters. Typically these are used in preparingpolyurethane-polyisocyanurate foams, and typically are di-functional.The second category comprises high functionality polyethers, havingfunctionalities of 3 to 10.

Aromatic polyester polyols used in rigid foams are typically preparedfrom phthalate type acids (any of the three commercial isomers),phthalate type esters, phthalic anhydride, or phthalate polymers such asPET by reaction thereof with low molecular weight glycols (typicallyless than 200 molecular weight). The preferred glycol for this purposeis diethylene glycol (DEG). This glycol tends to produce polyesterresins that are liquid and of sufficiently low viscosity for processingin a mixing activated system. The DEG is generally used in large excessover the aromatic precursor, and thereby acts as a reactive solvent forthe hydroxyl terminated polyester resin.

High functionality polyether polyols typically are prepared by reactingpropylene oxide with a high functionality initiator. These rigid polyolsare characterized by having lower equivalent weights (per —OH group)than flexible polyols. This is due to higher functionality at lowermolecular weight. The equivalent weights of these polyols typically areless than 300, more typically between 50 and 200. This compares withflexible polyols, which typically have hydroxyl equivalent weights ofgreater than 500. The initiators typically used in preparing rigidpolyether type polyols include sugars such as sucrose, and aromaticpolyamines such as the toluenediamines and the oligomeric condensates offormaldehyde with aniline. Each of the primary amine groups on thesearomatic polyamines reacts with two or more moles of propylene oxide.The rigid polyether polyols, like the aromatic ester polyols, typicallyare diluted with low molecular weight glycols such as DEG in order toachieve viscosities which are low enough for mixing activatedprocessing.

The rigid polyols (of either type) often are further compounded withlower molecular weight aliphatic glycols, triols, tetrols, andalkanolamines. Examples of these lower molecular weight polyols (whichgenerally have molecular weights of under 200) include ethylene glycol,diethylene glycol, triethylene glycol, propylene glycol, dipropyleneglycol, tripropylene glycol, the butanediols, glycerol,trimethylolpropane, diethanolamine, triethanolamine, dipropanolamine,tripropanolamine, mixtures of these, and the like.

The polymer matrices used rigid foams are almost always more highlycross-linked than those used in flexible foams. Much of thecross-linking in these polymers comes from the polyisocyanate. Thenumber averaged functionality of the polyisocyanates used in rigid foamstypically range from 2.5 to 3. Rigid polyisocyanurate-polyurethane isvery highly cross-linked due to the isocyanurate (trimer) linkages inthe polymer.

There is a continuum of foam types between “flexible” and “rigid”. Thesemay be called semi-rigid or semi-flexible. These foams may be preparedby using combinations of rigid and flexible polyols and polyisocyanatefunctionalities anywhere from 2 to 3, but most typically 2.5 to 2.8.These foams are used in a wide range of structural, energy absorbing,and decorative applications. A particularly important application ofsemi-rigid/semi-flexible foams is automotive poured-in-place dashboardpads and knee pads. These foams typically are poured in place behind adecorative flexible facing material such as a fabric or PVC. Densitiestypically range from 2 to 10 pounds per cubic foot (sometimes higher),depending on the application. Since these are non-insulationapplications, the foams are most typically water blown.

Higher density cellular polyurethanes, with densities ranging from above10 pounds per cubic foot to just short of full density, are sometimescalled “microcellular” polyurethanes. These are used in a wide range ofapplications, which include flexible shoe soles to rigid synthetic woodsubstitutes, and a spectrum of semi-rigid/semi-flexible applications inbetween these extremes. Microcellular flexible polyurethane shoe solesmay be prepared with integral skins. The skins form spontaneously due tolocalized collapse of the foam cells near the mold surface. The core ofthe foam remains cellular. This mechanism of integral skin formation ispromoted by using a volatile physical blowing agent, such as ahydrofluorocarbon that is liquid at ambient temperatures. Spontaneousskin formation occurs if the temperature of the mold surface is lowerthan the boiling point of the physical blowing agent. Integral skinfoams are also used in other applications, such as automotive armrestsand various furniture applications. Shoe sole foams are generallyprepared from formulations which consist entirely (or almost entirely)of difunctional monomers. Typically, the Index is 100% or sometimesslightly lower (99%). These polymers can be made from flexible diols(especially polyesters), low molecular weight diol chain extenders suchas 1,4-butanediol or ethylene glycol, and diisocyanates such as4,4′-diphenylmethane diisocyanate and semiprepolymers thereof. Thepolymers used in shoe sole foams are therefore essentially linear. Theblowing agent usually comprises small amounts of water. By contrast,rigid and semirigid/semiflexible microcellular foams are more highlycrosslinked. The selection of monomers is analogous to the lower densityanalogs. However; the higher density foams are usually closed celled. Atthe highest end of the polyurethane foam density spectrum are thereaction injection molded (RIM) elastomers. These can be blown entirelyby entraining small amounts of air (or nitrogen) into the liquidprecursor streams. This entraining process, sometimes called nucleation,amounts to whipping the gas into the liquid chemicals prior to mixing ofthe opposing streams and processing. RIM elastomers typically are formedfrom a polyisocyanate-reactive stream that comprises both a flexiblepolyol and a chain extender. The amount of chain extender is adjusted tocontrol the rigidity (or flexibility) of the elastomer. Examples oftypical chain extenders used to prepare these elastomers include lowmolecular weight glycols and aromatic diamines.

It is understood that the skilled artisan, using the methods andcompositions (for example, water-soluble protein fractions and/orwater-insoluble/water dispersible protein fractions, certainisocyanate-based reactants, certain isocyanate reactive compounds, andcertain additives) described herein can create foams having the desiredphysical and chemical properties, for example, density, rigidity,compressibility, resilience, etc. For example, if a foam with lowerdensity is desired, a water-soluble protein composition can be includedin the premix. In contrast, the inclusion of water-insoluble/waterdispersible protein fraction can be used to create foams with a higherdensity and/or with more structural integrity than can be achievedwithout a protein additive (for example, a water-soluble protein).Alternatively, a blend of the water-insoluble/water dispersible proteincan be used to create foams of the requisite features.

In certain embodiments, the isocyanate-based reactant constitutes fromabout 10% (w/w) to about 90% (w/w) of the starting materials used toprepare the foam. In certain other embodiments, the isocyanate-reactivecompound constitutes from about 10% (w/w) to about 90% (w/w) of thestarting materials used to prepare the foam. In certain otherembodiments, the protein containing composition (e.g., the water-solublepolypeptide composition) constitutes from about 0.01% (w/w) to about 50%(w/w) or from about 0.01% (w/w) to about 30% (w/w) or from about 0.01%(w/w) to about 10% (w/w) of the starting materials used to prepare thefoam. In certain other embodiments, the foam is produced at an Index inthe range from about 250% to about 800%.

It is also appreciated, for example, as demonstrated in Example 11, thatsmall amounts of the added protein compositions (e.g., crude material,protein isolates, or isolated water-soluble and/or water-insolubleproteins) in the foam pre-mix can have a profound effect on the physicalproperties of the resulting foams. In certain embodiments, the pre-mixcontains less than 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%,0.05%, or 0.01% by weight the protein composition. By way of example, inExample 11, the polyol blend (Part B) containing about 0.09% by weightof a water-soluble protein fraction was capable of modulating thedensity of the resulting foam.

In addition, the polypeptide composition can be designed to have aparticular polydispersity index. In addition, the polypeptidecomposition and the adhesive composition can be designed to have apolydispersity index. The term “polydispersity index” (PDI) refers tothe ratio between the weight average molecular weight M_(w) and thenumber average molecular weight M_(n) :

${PDI} = \frac{{\overset{\_}{M}}_{w}}{{\overset{\_}{M}}_{n}}$

The terms “number average molecular weight,” denoted by the symbol Mnand “weight average molecular weight,” denoted by the symbol Mw, areused in accordance with their conventional definitions as can be foundin the open literature. The weight average molecular weight and numberaverage molecular weight can be determined using analytical proceduresdescribed in the art, e.g., chromatography techniques, sedimentationtechniques, light scattering techniques, solution viscosity techniques,functional group analysis techniques, and mass spectroscopy techniques(e.g., MALDI mass spectroscopy). For instance, as illustrated in Example2, average molecular weight and number average molecular weight of thepolypeptide composition was determined by MALDI mass spectroscopy.Further, it is contemplated that polypeptide compositions havingdifferent molecular weights may provide foam compositions havingdifferent properties. As such, the weight average molecular weight,number average molecular weight, and polydispersity index can be animportant indicator when optimizing the features of the foamcomposition. Further, as described herein, the molecular weight of thepolypeptide composition can be altered by subjecting the proteinstherein to enzymatic digestion or fractionation of the polypeptidecomposition.

Further, it is contemplated that polypeptide compositions havingdifferent molecular weights may provide adhesive compositions havingdifferent properties. As such, the weight average molecular weight,number average molecular weight, and polydispersity index can be animportant indicator when optimizing the features of the adhesivecomposition. In particular, it is contemplated that the ability tooptimize the molecular weight characteristics of the polypeptidecompositions provides advantages when preparing an adhesive compositionfor a particular use. Further advantages include obtaining adhesivecompositions with similar properties even though the polypeptidecomposition may be obtained from a different source (e.g., soy vs.castor) or when similar protein sources are harvested during differentseasons, over varying periods of time, or from different parts of theworld. For example, proteins isolated from soy and castor (each havingdifferent molecular weight distributions) can be made to have similarmolecular weight distributions through digestion and fractionationprocesses described herein. Accordingly, the ability to measure andcontrol the consistency of molecular weight distributions iscontemplated to be beneficial when optimizing various features of theadhesive composition, e.g., long-term reproducibility of physicalproperties and process characteristics of formulated adhesives. Themolecular weight characteristics of the polypeptide composition can bealtered by subjecting the proteins therein to enzymatic digestion orfractionation according to the procedures described herein.

In certain embodiments, the PDI of the premixes used to produce the foamcompositions described herein is from about 1 to about 3, from 1 to 1.5,from 1.5 to 2, from 2 to 2.5, from 2.5 to 3, from 1 to 2, from 1.5 to2.5, or from 2 to 3.

VII. Applications of Foam

Numerous applications for foams have been described in the art, and thefoams described herein are contemplated to be amenable to a largevariety of applications. For example, flexible foams made using methodsdescribed herein may be molded (as in automobile seating), or poured asslabstock and subsequently cut to shape (as in furniture and bedding).Other important applications of flexible polyurethane foams includecarpet underlay.

The foams may also be used as insulation. It is understood that animportant physical property of insulation foams is thermoconductivity.In order to achieve the lowest possible thermocoductivity, rigid foamscan be blown with a volatile hydrofluorocarbons (such as thepentafluoropropanes). These physical blowing agents have lowerthermoconductivities than air or carbon dioxide. Water can be used as asecondary blowing agent. The density range for rigid insulation foamstypically is from 1.5 to 4 or from 2 to 2.5 pounds per cubic foot. Rigidfoams can be poured or injected in place, but are more commonly producedas laminated boardstock. The laminate boards subsequently are cut toshape and used in construction. Rigid insulation foams typically areclosed celled foams, in order to retain the low thermoconductivity(hydrofluorocarbon) blowing agent.

Rigid foams can also be used for purely structural applications, wherethermoconductivity is not a factor. An important example of a purelystructural application of rigid foams is automobile interior doorpanels. These materials are molded to shape and entirely water blown.They often are reinforced with glass fibers in order to enhancestructural strength. Short glass fibers can be added to the liquidprecursor streams, usually the isocyanate-reactive component. Morecommonly the structural reinforcement is provided in the form of glassmats or preforms which are pre-placed in the mold. The reactingfoam-forming mixture then is poured over the mat (before the mold isclosed) or injected through the mat. The foam then rises and flowsthrough the mat within the mold.

Foam can also be used as packaging. Foams for packaging are typicallywater blown, open celled, and of very low density. Foam densities inpackaging are typically below 2 pounds per cubic foot and may be lessthan 1 pound per cubic foot. These foams can be poured or injectedaround the objects to be packaged.

EXAMPLES

The invention now being generally described, will be more readilyunderstood by reference to the following examples, which are includedmerely for purposes of illustration of certain aspects and embodimentsof the present invention, and are not intended to limit the invention.

Example 1 Isolation of Polypeptide Compositions

Procedures for isolating and characterizing the water-solublepolypeptide composition, water-insoluble polypeptide composition, or amixture thereof are described below.

Procedure A: Preparation of Water-Soluble Polypeptide Composition andPreparation of Water-Insoluble Polypeptide Composition.

Everlase digested protein from castor (experimental sample lot 5-90) wasobtained from Prof. S. Braun at the Laboratory of the Department ofApplied Biology at the Hebrew University of Jerusalem, Israel. Digestedcastor can be prepared as follows: castor meal protein is suspended inwater at the ratio of about 1:10 w/w. Calcium chloride is added to aneffective concentration of about 10 mM, and the pH of the suspensionadjusted to pH 9 by the addition of 10 N NaOH. The reaction is thenheated to 55° C. while stirring. Next, Everlase 16L Type EX®(NOVOZYMES') is added at the ratio of 20 g per kg of castor mealprotein, and the mixture is stirred at the same temperature for about 4hours. Finally, the resulting mixture is brought to a pH 3.5 with citricacid and spray-dried to provide a powder.

The Everlase digested protein from castor (lot 5-90) was fractionated toyield a water-soluble fraction, and a water-insoluble, dispersiblefraction. In the first step, 300 g of digested castor was slurried into1 liter of distilled water. The mixture was shaken by hand, and was thenplaced into a sonicator bath for a period of 30 minutes. The slurry thenwas removed and was allowed to set idle for a period of up to two daysto allow the insoluble portion to settle (in separate experiments, itwas found that centrifuging was equally adequate). At that point, theclear yellow/amber supernatant was pipetted away and was retained forfuture use. Fresh distilled water was then added to the sediment tobring the total volume back to the 1-Liter mark on the container. Theprocess of shaking, sonicating, settling, supernatant extracting, andreplenishing with fresh distilled water (washing) then was repeated (6times in total). In the final step, the water was pipetted from the topof the grayish-black sediment, and the sediment was then dried in avacuum oven at 45° C. Based on the sediment's dry weight, thewater-insoluble/water dispersible polypeptide fraction was determined tocomprise of approximately 50% by weight of the digested castor.Separately, the 1^(st) and 2^(nd) supernatants were combined and werethen dried to yield a transparent yellow-colored, water-solublepolypeptide fraction.

After drying the fractions, it was verified that the grayish-blacksediment (the water-insoluble and dispersible fraction) could not bere-dissolved in water. On the other hand, the dried supernatant fraction(clear/amber, glassy solid) was completely soluble in water.

The two fractions were separately analyzed by solid state FTIR (seeFIGS. 2-4). The spectra in FIG. 2 show that carboxylate and amine saltmoieties are primarily associated with the water-soluble fraction. FIG.3 shows that the amide carbonyl stretch band and the amide N—H bendbands are shifted to higher wavenumbers in the water-soluble polypeptidefraction. These components also appear to be present in thewater-insoluble dispersible polypeptide fraction, but the predominantamide-I and amide-II bands are shifted to lower wavenumbers. Aside fromhydrogen bonding effects, these differences also appear to be related tothe presence of a higher fraction of primary amide groups in thewater-soluble polypeptide fraction, and to a higher fraction ofsecondary amide groups in the water-dispersible polypeptide fraction(from the main-chain polypeptide chains). This is corroborated by theN—H stretching region depicted in FIG. 4.

FIG. 4 shows solid state FTIR spectra of isolated fraction from digestedcastor where the N—H stretching region from FIG. 2 is expanded. Thespectra were vertically scaled to achieve equivalent absorbanceintensities for the secondary amide N—H stretch band centered at 3275cm⁻¹. FIG. 4 shows that the predominant type of amide in thewater-dispersible fraction is the secondary main-chain amide asevidenced by the single, highly symmetric band centered at 3275 cm⁻¹.Although the water-soluble fraction also contains this type of amide, italso contains significantly higher fractions of primary amides asevidenced by the presence of the two primary N—H stretching bands atapproximately 3200 cm⁻¹ (symmetric) and at approximately 3300 cm⁻¹(asymmetric), respectively.

These spectra show that the water-soluble polypeptide fraction combineda relatively high concentration of primary amines, free carboxylicacids, acid salts, and amine salts. Conversely, thewater-insoluble/water dispersible polypeptide fraction had a higherfraction of secondary amides. In addition, the amide-I carbonylabsorption band for the water-insoluble/dispersible fraction wasobserved to appear at a wavenumber of approximately 1625 cm⁻¹, whereasthat of the water-soluble fraction was observed at approximately 1640cm⁻¹. As will be discussed in other Examples, this feature is one of thedistinguishing differences between the water-soluble and water-insolublepolypeptide fractions; not only for castor proteins, but for soyproteins as well.

Procedure B: Additional Procedure for Preparation of Water-SolublePolypeptide Composition and Preparation of Water-Insoluble PolypeptideComposition.

Digested soy protein was obtained as an experimental sample (lot 5-81)from Prof. S. Braun, the Laboratory of Applied Biology at the HebrewUniversity of Jerusalem, Israel. The digested soy protein was preparedas follows. Soy protein isolate (Soy protein isolate SOLPRO 958® SolbarIndustries Ltd, POB 2230, Ashdod 77121, Israel) was suspended in waterat a ratio of 1:10 (w/w). The pH of the suspension was adjusted to pH 7with 10N NaOH, and was then heated to 55° C. while stirring. Neutrase0.8 L® (NOVOZYMES') then was added at a ratio of 20 g per kg of soyprotein, and the mixture was stirred at the same temperature for 4hours. The resulting mixture (pH 6.5) was spray-dried to yield a lighttan powder.

Digested soy (lot 5-81) was fractionated to yield a water-solublepolypeptide fraction, and a water-insoluble/water dispersiblepolypeptide fraction. In the first step, 300 g of digested soy wasslurried into 1 liter of distilled water. The mixture was shaken byhand, and was then placed into a sonicator bath for a period of 30minutes. Aliquots were placed into centrifuge tubes, and the tubes werethen spun at 3,400 rpm for a period of approximately 35 minutes. Thecentrifuged supernatant, which contained the water-soluble fraction, wasdecanted off of the remaining water-insoluble sediment, and was pouredinto a separate container for later use (this clear yellow supernatantwas placed into an open pan and was allowed to evaporate dry at atemperature of 37° C.). After the first washing step, fresh distilledwater was then added to the tubes, and the remaining sediment wasdispersed into the water by means of hand-stirring with a spatula. Thecombined centrifugation, decanting, and re-dispersion procedures wereperformed for a total of 5 cycles. After the final cycle, the freeliquid containing residual water soluble protein was decanted from theresidual paste-like dispersion (yellowish-peach in color). The resultingdispersion (gravimetrically determined to be 16.24% solids by weight)contained the water-insoluble/water dispersible proteins.

The paste-like dispersion was observed to be stable for a period ofseveral weeks. It was also discovered that the dispersion could bereadily combined with water-soluble polymers, and with water-dispersiblepolymer latexes. Moreover, the dispersion was readily compatible withPMDI (a stable dispersion was formed when PMDI was added to the slurry,and there was no evidence of PMDI phase separation, even after 24hours). By contrast, neither the water soluble extract from the digestedsoy, nor the digested soy itself was capable of stabilizing a dispersionof PMDI in water.

After drying aliquots of both fractions, it was verified that the yellowsediment (the water-insoluble/dispersible extract) could not bere-dissolved in water. On the other hand, the dried supernatant fraction(clear/yellow solid) was completely soluble in water. The two driedextracts were separately analyzed by solid state FTIR (see FIGS. 5-8).FIG. 6 shows overlaid solid state FTIR spectra of isolated fractionsfrom digested soy, where the N—H region is expanded. The spectra werevertically scaled to achieve equivalent absorbance intensities for thesecondary amide N—H stretch band centered at 3275 cm⁻¹. FIG. 6 showsthat the predominant type of amide in the water-dispersible fraction isthe secondary main-chain amide as evidenced by the single, highlysymmetric band centered at 3275 cm⁻¹. Although the water-solublepolypeptide fraction also contains this type of amide, it also containssignificantly higher fractions of primary amides as evidenced by thepresence of the two primary N—H stretching bands at approximately 3200cm⁻¹ (symmetric) and at approximately 3300 cm⁻¹ (asymmetric),respectively. Collectively, these spectra revealed that thewater-soluble polypeptide fraction was comprised of a relatively highconcentration of primary amines. Conversely, the water-insoluble,dispersible polypeptide fraction was comprised of a higher fraction ofsecondary amines.

As shown in FIG. 5, the amide carbonyl stretch band and the amide N—Hbend band are shifted to higher wavenumbers in the water-solublefraction. These components also appear to be present in thewater-insoluble dispersible fraction, but the predominant amide-I andamide-II bands are shifted to lower wavenumbers. Aside from hydrogenbonding effects, these differences appear to be related to the presenceof a higher fraction of primary amide groups (and/or primary amines) inthe water-soluble polypeptide fraction (from lower molecular weightamino acid fragments), and to a higher fraction of secondary amidegroups in the water-dispersible polypeptide fraction (from themain-chain polypeptide chains). This is supported by the N—H stretchingregion depicted in FIG. 6.

FIG. 6 shows that the predominant type of amide in the water-dispersiblefraction is the secondary main-chain amide as evidenced by the single,highly symmetric band centered at 3275 cm⁻¹. Although the water-solublefraction also contains this type of amide, it also containssignificantly higher fractions of primary amines as evidenced by thepresence of the two primary N—H stretching bands at 3200 cm⁻¹(symmetric) and at approximately 3300 cm⁻¹ (asymmetric), respectively.

In spite of being derived from different plant sources, thewater-insoluble dispersible fractions from digested soy and digestedcastor are spectrally similar to one another (see FIG. 7). Conversely,the water-soluble polypeptide fractions appear to have different FTIRspectral characteristics (see FIG. 8). Further, MALDI mass spectroscopicindicates the water-soluble polypeptide fractions from digested soy anddigested castor have different molecular weight characteristics. Thecommonality between the two types of water-soluble fractions is thatthey both appear to contain primary amines/amides.

Procedure C: Additional Procedure for Preparation of Water-SolublePolypeptide Composition and Preparation of Water-Insoluble PolypeptideComposition

Castor meal (4.0 kg containing 24.8% protein) was suspended in 0.1M NaOHat a 10:1 w/w meal to alkali ratio. The suspension was stirred for 18hours at ambient temperature and the solids were then removed bycentrifugation. The supernatant (about 32 liters) was acidified to pH4.5 with 10 N HCl. The protein was allowed to sediment at about 10° C.for 12 hours, the clear supernatant solution was decanted, and the heavyprecipitate (about 2 kg) was collected by centrifugation. The wetprecipitate was freeze-dried yielding 670 g protein isolate.

The water-insoluble and water-soluble polypeptide fractions wereobtained by means of extraction with water. In the first step, 10 g ofthe castor protein isolate (lot 5-94) was slurried into 50 g ofdistilled water. The mixture was dispersed via mechanical stirring for 2hours. Aliquots then were placed into centrifuge tubes, and the tubeswere then spun at 3,400 rpm for a period of approximately 35 minutes.The centrifuged supernatant, which contained the water-soluble fraction,was decanted from the remaining water-insoluble sediment, and was pouredinto a separate container (this clear yellow supernatant was saved anddried at 37° C. for subsequent dispersion experiments and solid stateFTIR analyses). After the first washing step, fresh distilled water wasthen added to the tubes, and the remaining sediment was dispersed intothe water by means of hand-stirring with a spatula. The combinedcentrifugation, decanting, and re-dispersion procedures were performedfor a total of 13 cycles. After the final cycle, the free liquid wasdecanted from the residual paste-like dispersion (the water-insolublepolypeptide fraction from the starting castor protein). Upon drying, thepaste was determined to contain 28.58% solids, and the total yield ofthe water-insoluble fraction was determined to be 62.87%. Thus, thestarting castor protein itself contained 62.87% water-insolublepolypeptide material, and 37.12% water-soluble polypeptide material.

Procedure D: Preparation of Digested Whey Protein.

Digested whey protein (lot 5-72, referred to herein as digested wheyprotein pH 6.5) was obtained as an experimental sample from Prof. S.Braun, the Laboratory of Applied Biology at the Hebrew University ofJerusalem, Israel, and was prepared as follows; Whey protein (WPI-95°Whey Protein Isolate; Nutritteck, 24 Seguin Street, Rigaud, QC, CanadaJ0P 1P0) was suspended in water at a ratio of 1:6 (w/w). The pH of thesuspension was adjusted to pH 7 with 5N NaOH, and was heated to 55° C.while stirring. FLAVOURZYME 500MG® (from NOVOZYMES') then was added at aratio of 20 g per kg of whey protein, and the mixture was stirred at thesame temperature for 4 hours. The resulting aqueous mixture was pH 6.5.The resulting mixture then was spray-dried to yield digested wheyprotein as a pale yellow powder containing a mixture of water-solubleand water-insoluble polypeptide.

Procedure E: Preparation of Digested Castor Protein Reacted with SodiumNitrite.

Castor meal protein was suspended in water at a ratio of 1:10 (w/w).Calcium chloride was added at an effective concentration of 10 mM, andthe pH of the suspension was adjusted to pH 9 by the addition of 10 NNaOH. The reaction was heated to 55° C. while stirring. Everlase 16LType EX® (NOVOZYMES') then was added at a ratio of 10 g per kg of castormeal protein, and the mixture was stirred at the same temperature for 4hours. L-lactic acid (90%, 120 g per kg castor protein) then was addedto bring the mixture to pH 4.4 followed by gradual addition (over a 20hour period) of sodium nitrite solution in water (0.4 kg/1, 0.4 literper kg castor protein) while stirring. The reaction then was left tostand at ambient temperature for 40 hours. Na₂S₂O₅ (0.2 kg per kg castorprotein) was then added, and the reaction was heated to 60° C. andstirred for 15 minutes. After cooling to ambient temperature, thereaction was brought to pH 2.0 with concentrated HCl. It was then leftat 10° C. for 18 hours, and the resulting precipitate was separated bycentrifugation for 15 minutes at 24,000×g. The precipitate wasre-suspended in 10 mM citric acid (3 vol. per vol. precipitate), andthen it was collected and subsequently freeze-dried to yield a tanpowder containing a mixture of water-soluble and water-insolublepolypeptide.

Example 2 Characterization of Polypeptide Compositions by MassSpectrometry

This Example describes characterization of the various protein samplesvia MALDI Mass Spectrometry using an Ultraflex III instrument fromBruker.

The instrument was set in positive mode, in order to detect positiveions generated during the ionization process. The voltage applied toaccelerate the ion into the TOF analyzer was set at 25 KV. The analysiswas carried out by using the instrument in reflection mode whichimproves the resolution. Solid samples were dissolved in DMSO at aconcentration of 10 mg/mL. Water-soluble supernatant fractions whichwere solvated in water.

Each sample solution was mixed with a matrix solution (for analyticalpurposes). The matrix was an inert compound of low molecular weightwhich absorbs at the same wavelength of the laser, Nd:YAG 355 nm. Thematrices used were: α-CHCA, alpha-cyano-4-hydroxycinnamic acid,dissolved in a solution of ACN/H₂O (70:30) with 0.1% of TFA at aconcentration of 10 mg/mL; and DCTB,T-2-[3-(4-t-Butyl-phenyl)-2-methyl-2-propenylidene]malononitrile,dissolved in THF at a concentration of 10 mg/mL. The first matrix wasmainly used for the analysis of peptides and proteins while the secondone, DCTB, was suitable for the analysis of polymers.

The matrix solutions and the sample solutions were mixed at a 10:1volume ratio respectively. For the analysis where DCTB was used asmatrix, NaTFA (10 mg/mL in THF) was added to the solution matrix/sampleas a cationizing agent at a ratio 10:2:1 by volume (matrix:sample:salt,respectively). 0.8 μL of the resulting solutions were spotted on atarget plate made of polished steel, and only after the solvents werecompletely dried was the target loaded into the instrument. The spectrawere collected and manipulated by using FlexAnalysis software releasedby Bruker Daltonics.

Relative fragment intensities were normalized and used to calculatenumber average (Mn), weight average (Mw), and z-average (Mz) molecularweight parameters for various samples. The results are summarized inTable 2.

TABLE 2 Sample ID Mn Mw Mz Mw/Mn Castor protein isolate lot 5-94 ¹ 11491162 1179 1.01 Digested castor lot 5-83 ² 951 1081 1250 1.13 Digestedcastor lot 5-108 ³ 897 1011 1169 1.12 Digested castor Water-insoluble/1009 1371 1928 1.35 dispersible fraction (lot 5-108) ³ Digested castorWater-soluble 1532 1697 1894 1.10 fraction (lot 5-108) ³ Soy ProteinIsolate 2023 2104 2161 1.03 Digested Soy (lot 5-81) ⁴ 894 989 1104 1.10Digested Soy Water-insoluble/ 910 1119 1512 1.22 dispersible fraction(lot 5-81) ⁴ Digested Soy Water-soluble 837 888 941 1.06 fraction (lot5-81) ⁴ ¹ see Example 1, Procedure C ² see Example 6 ³ see Example 3 ⁴see Example 1, Procedure B

The results indicate that the molecular weight characteristics (asdetermined by MALDI mass spectroscopy) of the polypeptide compositioncan depend on the process used to obtain the polypeptide composition.For example, castor protein isolate was observed to have a higher numberaverage molecular weight than its digested counterpart. Further, upondigestion, the number average molecular weight was observed to decreasewhile the polydispersity increased. The same trend was observed for thesoy protein isolate and its digested counterpart.

Other experimental results indicate that proteins in the water-solublepolypeptide composition from digested castor have a higher numberaverage molecular weight than its parent protein isolate. However,proteins in the water-soluble polypeptide composition from digested soyhad a lower number average molecular weight than its parent soy proteinisolate.

Nonetheless, each of these water-soluble polypeptide compositions wasable to facilitate a reduction in the density of polyurethane foamcompared to foams prepared without the polypeptide composition.Furthermore, water-soluble polypeptide compositions having similarmolecular weights and molecular weight distributions could be obtainedby enzymatic digestion of soy and castor protein isolates (even thoughthe soy protein isolate has higher molecular proteins than and castorprotein isolate prior to enzymatic digestion). Collectively, theseresults indicate that it is possible to prepare reduced-density foamsfrom a variety of polypeptide compositions.

Example 3 Oil Dispersion Characteristics of Water-Soluble andWater-Insoluble Protein Fractions

A water-insoluble/water dispersible polypeptide fraction and awater-soluble polypeptide fraction were isolated from digested castor(lot 5-108) based on procedures described in Example 1 (Procedure A).The digested castor can be prepared as follows: castor meal protein issuspended in water at the ratio of about 1:10 w/w. Calcium chloride isadded to an effective concentration of about 10 mM, and the pH of thesuspension adjusted to pH 9 by the addition of 10 N NaOH. The reactionis then heated to 55° C. while stirring. Next, Everlase 16L Type EX®(NOVOZYMES') is added at the ratio of 10 g per kg of castor mealprotein, and the mixture is stirred at the same temperature for about 4hours. Finally, the resulting mixture is brought to a pH 3.5 with citricacid and spray-dried to provide a powder.

The MALDI fragmentation molecular weight characteristics of the isolatedfractions are provided in Example 2 (Table 2). The solid state FTIRspectroscopic absorption characteristics for the isolatedwater-insoluble/dispersible polypeptide fraction conform with those asdescribed in FIGS. 2, 3, 4, 7, 9, 10, 11 and 12 (amide-I absorptionrange: 1620-1632 cm⁻¹; amide-II absorption range: 1514-1521 cm⁻¹).Solution state two-dimensional proton-nitrogen coupled NMR on theisolated water-insoluble/dispersible polypeptide fraction show twoprotonated nitrogen clusters enveloped by ¹⁵N chemical shift boundariesat approximately 86.2 ppm and 87.3 ppm; and with ¹H chemical shiftboundaries at approximately 7.14 and 7.29 ppm for the first cluster; andat approximately 6.66 and 6.81 ppm for the second cluster. Solutionstate two-dimensional proton-nitrogen coupled NMR on the isolatedwater-soluble polypeptide fraction show a cluster of protonated nitrogennuclei defined by ¹⁵N chemical shift boundaries at about 94 ppm and atabout 100 ppm, and ¹H chemical shift boundaries at about 7.6 ppm and atabout 8.1 ppm.

Surprisingly, the water-insoluble/water dispersible polypeptidefractions with these spectral characteristics (unlike theirwater-soluble counterparts) exhibit the unique ability to emulsify andstabilize dispersions of oil in water and water in oil. This uniqueoil-dispersing capability is observed with water-insoluble/waterdispersible polypeptide compositions that are extracted and isolatedfrom multiple sources, including but not limited to (1) whole meals orprotein-isolates from either soy, canola, or castor that are extractedof their water-soluble polypeptide components at or near pH-neutralconditions; (2) whole meals or protein-isolates from soy, canola orcastor that are subjected to base catalyzed hydrolysis followed by acidaddition and subsequent extraction of water-soluble polypeptidecomponents; (3) whole meals or protein-isolates from soy, canola orcastor that are subjected to acid catalyzed hydrolysis followed by baseaddition and subsequent extraction of their water-soluble polypeptidecomponents; (4) whole meals or protein-isolates from soy, castor, orcanola that are subjected to combinations of base catalyzed hydrolysiswith enzyme digestion followed by acid addition and subsequentextraction of water-soluble polypeptide components.

It is understood that the stabilization of an oil-in-water orwater-in-oil emulsion/dispersion depends on several factors, includingbut not limited to the presence or absence of a stabilizing entity suchas a surfactant or a dispersant; the nature of the oil (i.e., itspolarity, hydrophilicity, hydrophobicity, solubility parameter, etc.);the nature of the surfactant or dispersant (i.e., HLB value, chargecharacteristics, molecular weight, water solubility, oil solubility,etc.); the ionic strength of the water-phase; the presence or absence ofadditives and impurities in either the oil or water phases; theconcentration of the oil (i.e., its weight percent in water); and theconcentration of the stabilizing entity. It is further understood thatthe efficiency of a stabilizing entity (a “stabilizing entity” being adispersant, an emulsifier, a surfactant, or thewater-insoluble/dispersible polypeptide composition of the presentinvention) is often judged according to its ability stabilize anemulsion for some specified period of time (i.e., to prevent themacroscopic phase separation of immiscible oil and water componentsunder shear or under static conditions).

In order to further demonstrate the generality of this finding, severaloil-in-water dispersions were prepared with a water-insoluble/waterdispersible polypeptide composition that was isolated from a digestedcastor protein. The water-insoluble/water dispersible polypeptidefraction was isolated as a paste-like dispersion in water. The paste wasdiluted with water to 16% solids, and separately to 14% solids. In thenext step, 3-gram aliquots of each paste were separately weighed into 15mL plastic beakers. Next, aliquots of the oils shown in Table 3 wereseparately added to individual paste aliquots at a ratio of 1 part oilto 1 part solid water-insoluble/water dispersible polypeptidecomposition on a weight basis (20 mixtures in total). The mixtures werestirred by hand with a spatula, and were observed to form homogenouscreams. The creams remained homogeneous with no visible signs ofmacroscopic phase separation for prolonged periods of time after mixingincluding periods ranging from 1 minute after mixing, 5 minutes aftermixing, 10 minutes after mixing, 15 minutes after mixing, 30 minutesafter mixing, 1 hour after mixing, and 2 hours after mixing. Bycontrast, the analogous water-soluble extract from the digested castorwas incapable of stabilizing dispersions of the oils in water.

TABLE 3 Oil type Source PMDI Rubinate-M from Huntsman CorporationMineral oil Drakeol 35 from Penreco Soybean oil RBD from ADM ProcessingCo. Motor oil Castrol Syntec, 5W-50 Castor oil Pale Pressed Castor Oilfrom Alnor Oil Company, Inc. Dibutyl Phthalate 99% from Acros Epoxidizedsoybean oil From Aldrich Caprylic triglyceride Neobee M-5 from StepanCo. Eucalyptus oil From Aromas Unlimited Tributyl o-acetylcitrate 98%from Aldrich

Protein compositions not enriched for the water-insoluble/waterdispersible fractions are unable to disperse oils. For example, a 16%solids dispersion of soy protein isolate, Lot 5-81, (Soy protein isolateSOLPRO 958® Solbar Industries Ltd, POB 2230, Ashdod 77121, Israel;protein content approximately 90%) was prepared by adding 32 grams ofsoy protein isolate to 168 grams of water at a pH of approximately 4 to6 (JM-570-1). Seven 10 gram aliquots of JM-570-1 were weighed into 20 mLdisposable beakers. A 10 gram aliquot contained 1.6 grams of soy proteinisolate and 8.4 grams of water. Seven different oils (namely, PMDI,mineral oil, soybean oil, motor oil, castor oil, dibutyl phthalate andepoxidized soybean oil, see Table 53) were added separately at a w/wratio of 1 part oil to 1 part protein solids (1.6 grams oil was added toeach 10 gram aliquot). The mixtures were stirred by hand with a spatula.None of the oils was observed to be dispersible in the 16% solidsdispersion of the soy protein isolate.

Example 4 Characterization of Polypeptide Compositions byTwo-Dimensional Proton-Nitrogen NMR Correlation Spectra andCharacterization of a Water-Insoluble/Water Dispersible PolypeptideFraction

The water-insoluble and water soluble protein fractions were prepared asfollows. Digested castor (lot 5-83) was suspended in water at the ratioof 1:10 w/w. Calcium chloride was added to the effective concentrationof 10 mM, and the pH of the suspension was adjusted to pH 9 by theaddition of 10 N NaOH. The reaction was heated to 55° C. while stirring.Everlase 16L Type EX® (NOVOZYMES') then was added at the ratio of 10 gper kg of castor meal protein, and the mixture was stirred at the sametemperature for 4 hours. The resulting mixture then was brought to a pH3.5 with citric acid and was spray-dried to yield a tan powder. Then,the water-insoluble and water soluble protein fractions were harvestedas described in Example 1 (Procedure A) and were allowed to air-dry at23° C.

The dried powder containing the water-insoluble protein fraction wasdissolved in d6-DMSO (6.8% by weight) to yield a red homogeneoussolution (Sample A). An aliquot of the as-made dried digested castor wasalso dissolved in d6-DMSO (6.8% solids by weight) to yield a comparativehomogeneous red solution (Sample B). Solid-state FTIR analyses of thesame dried powders revealed distinct differences in both the N—Hstretching and carbonyl stretching regions of the solid state FTIRspectra. These spectral differences were attributed to differences inbonding environments for the polypeptide N—H moieties, possiblyresulting from differences in secondary and tertiary structure. One ofthe specific differences involved a shift to lower wavenumbers for theamide-I carbonyl band in the water-insoluble/water dispersible fraction.In order to further characterize these types of differences, atwo-dimensional NMR technique was employed for the purpose ofcharacterizing a very specific subset of bonded atomic nuclei; namely,protons bonded to nitrogens.

The samples were dissolved in DMSO-d6 and were placed into 5 mm NMRtubes. All ¹H NMR spectra were recorded on a Varian INOVA 750 MHzspectrometer equipped with an HCN-PFG (pulsed field gradient) tripleresonance Cryo Probe at 30° C. For one-dimensional (1D) ¹H NMR spectra,a spectral window of 10000 Hz was used with an acquisition time of 3seconds and relaxation delay of 5 seconds. The spectra were signalaveraged for 16 transients using a proton 90° pulse width of 8.6microseconds. The spectral data were zero filled to 132k points and wereprocessed with 1 Hz line broadening, then baseline corrected andreferenced to an internal residual solvent DMSO-d6 peak at 2.50 ppmbefore integrating and making plots.

Phase sensitive two-dimensional (2D) ¹H-¹⁵N gradient-HSQC (heteronuclearsingle quantum coherence) data were collected with 2048 acquisitionpoints in the F2 dimension and 768 points in the F1 dimension (90° pulsewidths of 6.3 microseconds, and 33.5 microseconds were used for protonand nitrogen, respectively) 48 transients were collected for eachincrement, with a repetition delay of 1.2 seconds and acquisition timeof 0.124 seconds with GARP decoupling during acquisition. The acquireddata were processed with sine bell weighting and zero filled to8196×8196 points in F2 and F1 dimensions before final transformation toproduce the 2D correlation data.

The results are presented in FIGS. 13 and 14. FIG. 13 represents thetwo-dimensional HSQC¹H-¹⁵N NMR spectrum for digested castor lot 5-83 ind6-DMSO. The y-axis represents ¹⁵N chemical shift scale (ppm), and thex-axis represents ¹H chemical shift scale (ppm). The peaks within thespectrum represent protonated nitrogen atoms from all of the fractionsthat were present within the as-made digested castor (i.e., thewater-insoluble/water dispersible polypeptide fractions plus thewater-soluble polypeptide fractions). The multiple peaks in region Bwere observed to disappear upon removal of the water-soluble fractions(see FIG. 14). This indicates that these protonated nitrogens arespecific to the water-soluble polypeptide fractions, whereas at least aportion of the peaks in region A are specific to thewater-insoluble/water dispersible fraction.

FIG. 14 represents the two-dimensional HSQC¹H-¹⁵N NMR spectrum for thewater-insoluble/dispersible polypeptide extract from digested castor lot5-83 in d6-DMSO. The y-axis represents ¹⁵N chemical shift scale (ppm),and the x-axis represents ¹H chemical shift scale (ppm). The peakswithin the spectrum represent protonated nitrogen atoms from thewater-insoluble/water dispersible polypeptide fraction. The peaks withinRegion B were observed to be very weak in comparison to the analogouspeaks within the digested castor before extraction (see FIG. 13).Conversely, the remaining peaks were predominantly from the protonatednitrogens in Region A. This indicates that these particular protonatednitrogens are specific to the water-insoluble polypeptide fractions.

As shown in FIG. 14, the peaks within the spectrum represent protonatednitrogen atoms that are specific to the water-insoluble/waterdispersible polypeptide fraction. Upon expansion, the two “peaks” appearas narrow clusters that can be readily defined by the ¹⁵N and ¹Hchemical shift boundaries that define them: the ¹⁵N boundaries for bothclusters occur at approximately 86.2 ppm and 87.3 ppm; and the ¹Hboundaries occur at approximately 7.14 and 7.29 ppm for the firstcluster; and at approximately 6.66 and 6.81 ppm for the second cluster.

The results of these studies revealed that while the water-solublepolypeptide fraction was composed of multiple types of protonatednitrogen atoms (see FIG. 13), the water-insoluble/water dispersiblefraction contained significantly fewer types of protonated nitrogens,and was predominantly characterized by the presence of two majorproton-nitrogen cross peak clusters (see FIG. 14). These differences,like those as seen by solid state FTIR, illustrate that the chemicalbonding environments within the water-soluble polypeptide fraction aredistinctly different from those that exist within thewater-insoluble/dispersible fraction.

Together, the solid state FTIR and NMR data also characterize thewater-insoluble/dispersible polypeptide fraction, where there is asolid-state infrared amide-I absorption band between 1620-1632 cm⁻¹; asolid-state infrared amide-II absorption band between 1514-1521 cm⁻¹;and a solution-state pair of protonated nitrogen clusters as determinedby a ¹H-¹⁵N nuclear magnetic resonance correlation technique. Morespecifically, when the pair of protonated nitrogen clusters is observedby means of NMR with deuterated d6-DMSO as the solvent using atwo-dimensional HSQC¹H-¹⁵N NMR technique, the clusters are defined bythe ¹⁵N and ¹H chemical shift boundaries that define them: the ¹⁵Nboundaries for both clusters occur at approximately 86.2 ppm and 87.3ppm; and the ¹H boundaries occur at approximately 7.14 and 7.29 ppm forthe first cluster; and at approximately 6.66 and 6.81 ppm for the secondcluster.

Together, the solid state FTIR and NMR data characterize thewater-soluble polypeptide fraction, where there is a solid-stateinfrared amide-I absorption band between about 1633-1680 cm⁻¹; asolid-state infrared amide-II absorption band between 1522-1560 cm⁻¹;two prominent 1° amide N—H stretch absorption bands centered at about3200 cm⁻¹, and at about 3300 cm⁻¹, as determined by solid state FTIR,and a prominent cluster of protonated nitrogen nuclei defined by ¹⁵Nchemical shift boundaries at about 94 ppm and at about 100 ppm, and ¹Hchemical shift boundaries at about 7.6 ppm and at about 8.1 ppm, asdetermined by solution state, two-dimensional proton-nitrogen coupledNMR.

Example 5 Preparation of Protein-Containing Polyurethane Foam

In this Example, polyurethane foams containing water-soluble digestedcastor protein were prepared and characterized.

A—Extraction of Proteins by Polyol Blends

Sample JM-69-1 was prepared by adding 45 parts of Polyol (i.e., JEFFOLPPG-2000 from Huntsman Corporation) into a glass reaction vessel. Then,5 grams of digested castor protein (Lot 5-83) was added to the Polyolwith stirring using a high-speed rotary mixer while heating, and held ata temperature of 95° C. for a total reaction time of one hour.

Sample JM-69-2 was prepared by adding 43 parts of Polyol (i.e., JEFFOLPPG-2000 from Huntsman Corporation) and 2 parts distilled water into aglass reaction vessel. The Polyol/water blend was stirred using ahigh-speed rotary mixer until it was homogenous and transparent. Then, 5grams of digested castor protein (Lot 5-83) was added while the blendwas stirred. The sample was stirred using a high-speed rotary mixerwhile heating, and held at a temperature of 95° C. for a total reactiontime of one hour.

Both during and after the reaction, sample JM-69-1 was a homogeneous,brown translucent material. In contrast, sample JM-69-2 behaved muchdifferently during the reaction. At the start of the reaction, thesample looked similar to JM-69-1. At a temperature of approximately 85°C. phase separation was observed and the castor protein agglomerated andprecipitated leaving a clear, slightly yellow supernatant material.After sitting on the bench top for 24 hours and settling, sample JM-69-1had a cloudy supernatant above the sediment and the JM-69-2 samplelooked the same as it did immediately after the reaction.

The same supernatant trend was observed with samples, JM-69-3 andJM-69-4, which were prepared at room temperature (not heated and reactedas in JM-69-1 & JM-69-2). The only visual difference appeared to be thatthe digested castor protein in sample containing water did notagglomerate in the same way as the heated and reacted sample (JM-69-2).

In a subsequent series of experiments, digested soy protein (Lot 5-81)and digested whey protein (Lot 5-80) were prepared using the methoddescribed for sample JM-69-2. In these experiments, the protein did notagglomerate and precipitate during the reaction. However, after sittingon the bench top and cooling, the soy and whey proteins did settle tothe bottom of the reaction vessel resulting in a layer of supernatant ontop of the settled proteins.

B—Preparation of Polyurethane Foams

To confirm that the chemical species extracted from the proteincomposition was compatible with the blowing of foam, several foamsamples were prepared from the supernatants of samples JM-69-2, JM-71-1,and JM-71-2. The supernatant was used because, without wishing to bebound by a particular theory, it is believed that the supernatantcontains water-soluble polypeptide that has been extracted by the polyol(see Example 14). In addition, a control sample was prepared in the sameway as samples JM-69-2, JM-71-1, and JM-71-2 except that nowater-soluble protein was added to the polyol/water blend. The controlpolyol/water blend was heated using the same heating profile describedabove. The control blend was labeled sample JM-74-1.

Foam 75-3 was prepared by mixing the following components: 7.1 grams ofcontrol blend JM-74-1, 1.6 grams Jeffol A-630 from Huntsman Corporation,0.06 grams JEFFCAT DMDLC from Huntsman Corporation, and 0.06 partsdibutyltin dilaurate from Air Products & Chemicals, Inc. in a 150 mldisposable beaker. The polyol blend was mixed thoroughly with a spatulaand vortex mixer. Then, 9 grams of PMDI (RUBINATE-M from HuntsmanCorporation) was added to the beaker and mixed thoroughly with a spatulaby hand, and then allowed to rise freely in the beaker.

Foam JM-75-4 was prepared in the same way except that 7.1 grams of thesupernatant from sample JM-69-2 was used instead of JM-74-1. FoamJM-75-5 used 7.1 grams of the supernatant from sample JM-71-1 instead ofJM-74-1 and foam JM-75-6 used 7.1 grams of the supernatant from sampleJM-71-2 instead of JM-74-1.

Another foam control sample (JM-75-2) was prepared having the followingformulation: 7.1 grams of JEFFOL PPG-2000 from Huntsman Corporation, 1.6grams JEFFOL A-630 from Huntsman Corporation, 0.06 grams JEFFCAT DMDLCfrom Huntsman Corporation, and 0.06 parts dibutyltin dilaurate from AirProducts & Chemicals, Inc. and 0.39 grams of distilled water. The polyolblend was prepared in a 150 mL disposable beaker and thoroughly with aspatula and vortex mixer. Then 9 grams of PMDI (RUBINATE-M from HuntsmanCorporation) was added to the beaker and mixed thoroughly by hand with aspatula, and then allowed to rise freely in the beaker. This controlformulation used the same ratio of water to polyol as was used in thepreparation of control polyol blend JM-74-1 except this sample was not“cooked.”

Foams obtained using protein supernatant each had high rise and a tightcell structure. Pictures of the foams are provided in FIG. 16, andfurther observations from the experiment are provided in Table 4 below.

TABLE 4 Density Sample Description Observations (g/cm) JM-75-2 Control-1Course foam cell structure 0.218 JM-75-3 Control-2 Very little rise,very dense foam, 0.350 tacky to the touch JM-75-4 Supernatant High rise,small, tight cell 0.103 JM-69-2 structure JM-75-5 Supernatant High rise,slight collapse, small, 0.134 JM-71-1 tight cell structure JM-75-6Supernatant High rise, slight collapse, small, 0.119 JM-71-2 tight cellstructure

The data indicate that a water-soluble proteins harvested from thesupernatant derived from digested castor enhances the rise ofpolyurethane foams and facilitates a very uniform, small cell structurein the foam. Without wishing to be bound by theory, it is believed thatthe protein acts as a surfactant that allows for efficient mixing of thereacting components and nucleation of the evolved carbon dioxide gasallowing for a high foam rise, uniform cell structure, and lower densityfoam (other than the polypeptide, none of the materials used to preparethe foam are believed to act as a surfactant).

Example 6 Preparation of Polyurethane Foams Containing Digested Protein

In this Example, a series of polyurethane foams were prepared bycombining an isocyanate, a polyol blend, and dispersed agriculturalproteins. The presence of the dispersed proteins resulted inpolyurethane foams that rose to a higher height and had a smallercellular structure and lower density.

The isocyanate used for the “A” component was RUBINATE-M, polymericdiphenylmethane diisocyanate (PMDI) from Huntsman Corporation. Thecomposition of the polyol blend or “B” component contained 71.4 partsJEFFOL PPG-2000 from Huntsman Corporation, 15.6 parts of Jeffol A-630from Huntsman Corporation, 3.0 parts distilled water, 0.6 JEFFCAT DMDLCfrom Huntsman Corporation, and 0.6 parts dibutyltin dilaurate from AirProducts & Chemicals, Inc. The “B” component was denoted as sampleJM-37-1. Digested soy protein isolate (Lot 5-81), Whey proteinproteolyzed with Flavourzyme (Lot 5-80), and castor meal proteindigested with Everlast (Lot No. 5-83) were obtained from Prof. SergeiBraun of The Hebrew University of Jerusalem.

A series of comparative cup foam samples were prepared by adding 9 gramsthe polyol blend described above (sample JM-37-1) into a 250 mldisposable beaker and then 1 gram of a specific protein from the listdescribed above was added. The protein/polyol blends were mixed using aspatula and a vortex mixer to disperse the protein. The total sampleweight for the polyol/protein “B” components was 10 grams. 10 grams ofcomponent “A” (PMDI) was added to the “B” component in the beaker andwas mixed thoroughly by hand with a spatula, and then allowed to risefreely in the beaker. The protein containing foams were compared to acontrol foam consisting of 10 grams of the polyol blend described above(JM-37-1) reacted with 10 grams of PMDI. All of the components for theexperiments were at ambient temperature (23° C.). All the foam reactionswere conducted at ambient temperature.

Foam containing the dispersed soy, whey, and castor proteins rose higherthan the control foam. The resulting densities of these foams are setforth in Table 5.

TABLE 5 Density Sample Description (g/cm) JM-67-1 Polyol Blend JM-37-1 +Soy Protein 0.042 JM-67-3 Polyol Blend JM-37-1 + Whey Protein 0.034JM-67-5 Polyol Blend JM-37-1 + Castor Protein 0.035 JM-67-7 Polyol BlendJM-37-1 Control 0.056

In addition to the density changes, there were differences in the cellstructure of the resulting foams. The foams made with the soy and wheyproteins (JM-67-1 and JM67-3 respectively) had smaller and tighter cellsas compared to the foam made with castor protein (JM-67-5) and thecontrol (JM-67-7) which both had larger, coarser cell structure.

Example 7 Foam Prepared Using Either Digested Castor Protein orDerivatized, Digested Castor Protein

In this Example, polyurethane foam was prepared using digested castorprotein and using derivatized, digested castor protein.

A series of comparative cup foam samples were prepared by adding 9 gramsthe polyol blend described in Example-6 (sample JM-37-1) into a 250 mLdisposable beaker and then adding 1 gram of digested Castor protein (Lot5-83) or derivatized, digested castor protein (Lot 5-82). The proteinand polyol blend were mixed using a spatula and a vortex mixer todisperse the protein. The total sample weight for the polyol/protein “B”components was 10 grams. Then, 10 grams of component “A” (PMDI) wasadded to the “B” component in the beaker, and were mixed thoroughly byhand with a spatula, and then allowed to rise freely in the beaker. Theprotein containing foams were compared to two control foams: Control-1consisting of 9 grams of the polyol blend described above (JM-37-1)reacted with 10 grams of PMDI and Control-2 consisting of 10 grams ofthe polyol blend described above (JM-37-1) reacted with 10 grams ofPMDI. All of the components for the experiments were at ambienttemperature (23° C.). The foam forming reactions were conducted atambient temperature.

The foams containing the dispersed castor proteins rose higher than thecontrol foam. The resulting densities of these foams can be seen inTable 6.

TABLE 6 Density Sample Description (g/cm) JM-59-2 Polyol Blend JM-37-1 +Castor Protein 0.057 JM-59-3 Polyol Blend JM-37-1 Control-1 0.089JM-59-4 Polyol Blend JM-37-1 Control-2 0.113 JM-59-5 Polyol BlendJM-37-1 Derivatized, 0.056 Digested Castor Protein

Example 8 Comparison of Different Loadings of Digested Whey Protein onthe Resulting Foam

In this Example, polyurethane foam was prepared using either 10% (wt/wt)or 20% (wt/wt) of digested whey protein.

Two comparative cup foam samples were prepared. A first sample, JM-43-1,was prepared by adding 9 grams the polyol blend described in Example-6(sample JM-37-1) into a 250 mL disposable beaker and then adding 1 gramof Flavourzyme digested Whey protein (Lot No. 5-80) into the polyolblend. After the protein was added to the polyol blend, the compositionwas mixed using a spatula and a vortex mixer to disperse the protein.The total sample weight for the polyol/protein “B” components was 10grams. Then, 10 grams of component “A” (PMDI) was added to the “B”component in the beaker and was mixed thoroughly by hand with a spatula,and then allowed to rise freely in the beaker.

A second sample, JM-43-2, was prepared by adding 8 grams the polyolblend described in Example-2 (sample JM-37-1) into a 250 mL disposablebeaker and then adding 2 grams of Flavourzyme digested Whey protein (LotNo. 5-80) into the polyol blend. After the protein was added to thepolyol blend, the composition was mixed using a spatula and a vortexmixer to disperse the protein. The total sample weight for thepolyol/protein “B” components was 10 grams. 10 grams of component “A”(PMDI) was added to the “B” component in the beaker and was mixedthoroughly by hand with a spatula, and then allowed to rise freely inthe beaker. All of the components for the experiments were at ambienttemperature (23° C.). All the foam reactions were conducted at ambienttemperature.

The polyol/protein blend for sample JM-43-2 was higher in viscositycompared to polyol/protein blend JM-43-1. However, the resulting foamsrose to approximately the same height. The cell structure of each foamwas similar. The relative bulk densities for the middle section of eachsample are set forth in Table 7, where M1 denotes a one-inch thickcross-section cut below the center of the risen foam and M2 denotes theone inch thick cross-section cut above the center of the risen foam.

TABLE 7 Density Sample Description (g/cm) JM-43-1 Polyol Blend JM-37-1 +10% Flavourzyme 0.042 digested Whey Protein, cut M-1 JM-43-1 PolyolBlend JM-37-1 + 10% Flavourzyme 0.039 digested Whey Protein, cut M-2JM-43-2 Polyol Blend JM-37-1 + 20% Flavourzyme 0.040 digested WheyProtein, cut M-1 JM-43-2 Polyol Blend JM-37-1 + 20% Flavourzyme 0.037digested Whey Protein, cut M-2

In the resulting foam, the bottom section of the cup foam wasapproximately 1 inch thick, M-1 was the first middle section of the foamabove the bottom section was approximately 1 inch thick, and M-2 was thesecond middle section of the foam above M-1 and was approximately 1 inchthick. It is believed that the polyol blend extracts water-solubleproteins from the digested whey protein and contributes to the efficientfoam rise and small cell structure. When these foams are compared to thecontrol foams (JM-59-3 and JM-59-4) in Example 7, the density of all thefoams in Table 7 were observed to have lower density than the controlfoams.

Example 9 Polyurethane Foam Made Using Flavourzyme Digested WheyProteins of Differing pH

This Example describes the preparation and characterization ofpolyurethane foams using Flavourzyme digested whey proteins of differentpH.

A series of cup foam samples were prepared comparing Flavourzymedigested Whey protein prepared in two ways. A first sample, JM-40-1, wasprepared by adding 9 grams the polyol blend described in Example 6(sample JM-37-1) into a 250 mL disposable beaker and then adding 1 gramof Flavourzyme digested Whey protein (Lot 5-72) into the polyol blend.After the protein was added to the polyol blend, the composition wasmixed using a spatula and a vortex mixer to disperse the protein. Thetotal sample weight for the polyol/protein “B” components was 10 grams.Then, 10 grams of component “A” (PMDI) was added to the “B” component inthe beaker and was mixed thoroughly by hand with a spatula, and thenallowed to rise freely in the beaker.

A second sample, JM-40-2, was prepared by adding 9 grams the polyolblend described in Example 6 (sample JM-37-1) into a 250 mL disposablebeaker and then adding 1 gram of Flavourzyme digested Whey protein (LotNo. 5-80) into the polyol blend. After the protein was added to thepolyol blend, the composition was mixed using a spatula and a vortexmixer to disperse the protein. The total sample weight for thepolyol/protein “B” components was 10 grams. Then, 10 grams of component“A” (PMDI) was added to the “B” component in the beaker and was mixedthoroughly by hand with a spatula, and then allowed to rise freely inthe beaker. All of the components for the experiments were at ambienttemperature (23° C.). All the foam reactions were conducted at ambienttemperature.

A third sample, JM-40-5, was prepared by adding 8 grams the polyol blenddescribed in Example-6 (sample JM-37-1) into a 250 mL disposable beakerand then adding 2 grams of Flavourzyme digested Whey protein (Lot No.5-80) into the polyol blend. After the protein was added to the polyolblend, the composition was mixed using a spatula and a vortex mixer todisperse the protein. The total sample weight for the polyol/protein “B”components was 10 grams. Then, 10 grams of component “A” (PMDI) wasadded to the “B” component in the beaker and was mixed thoroughly byhand with a spatula, and then allowed to rise freely in the beaker. Allof the components for the experiments were at ambient temperature (23°C.). All the foam reactions were conducted at ambient temperature.

The protein containing foams were compared to two control foams:Control-1 (JM-40-3) containing 9 grams of the polyol blend describedabove (JM-37-1) reacted with 10 grams of PMDI and Control-2 (JM-40-4)containing 10 grams of the polyol blend described above (JM-37-1)reacted with 10 grams of PMDI. All of the components for the experimentswere at ambient temperature (23° C.). All the foam reactions wereconducted at ambient temperature.

Images of the foams produced from the above procedures are shown in FIG.17. Foam prepared with Flavourzyme digested Whey protein Lot No. 5-80,(samples JM-40-2 and JM-40-5) which has a pH of approximately 3.5, rosehigher than foam sample JM-40-1 prepared with Flavourzyme digested Wheyprotein Lot No. 5-72 having a pH of approximately 6.0. In addition, foamprepared with Flavourzyme digested Whey protein Lot No. 5-80, (samplesJM-40-2 and JM-40-5) which has a pH of approximately 3.5, rose higherthan the control foam samples (i.e., JM-40-3 and JM-40-4). Density ofeach of the foam samples is set forth in Table 8.

TABLE 8 Density Sample Description (g/cm) JM-40-1 Polyol Blend JM-37-1 +10% Flavourzyme 0.056 digested Whey Protein, Lot No. 5-72, pH ~6.0JM-40-2 Polyol Blend JM-37-1 + 10% Flavourzyme 0.049 digested WheyProtein, Lot No. 5-80, pH ~3.5 JM-40-5 Polyol Blend JM-37-1 + 20%Flavourzyme 0.047 digested Whey Protein, Lot No. 5-80, pH ~6.0 JM-40-3Polyol Blend JM-37-1 Control-1 0.060 JM-40-4 Polyol Blend JM-37-1Control-2 0.072

Example 10 Foam Prepared Using a Water Soluble Polypeptide CompositionObtained from Digested Castor Protein

This Example describes the preparation of polyurethane foam preparedusing a water soluble polypeptide composition obtained from digestedcastor protein.

A—Preparation of Polypeptide Composition

Digested castor protein (Lot No. 5-108) was obtained as an experimentalsample (“digested castor”) from Prof. S. Braun, the Laboratory ofApplied Biology at the Hebrew University of Jerusalem, Israel. Thedigested castor was prepared as follows: Castor meal protein wassuspended in water at the ratio of 1:10 w/w. Calcium chloride was addedto the effective concentration of 10 mM, and the pH of the suspensionwas adjusted to pH 9 by the addition of 10 N NaOH. The reaction washeated to 55° C. while stirring. Everlase 16L Type EX® (NOVOZYMES') thenwas added at the ratio of 10 g per kg of castor meal protein, and themixture was stirred at the same temperature for 4 hours. The resultingmixture then was lowered to pH 3.5 with citric acid and was spray-driedto yield a tan powder.

The digested castor was fractionated to yield a water-solublepolypeptide fraction, and a water-insoluble/water dispersiblepolypeptide fraction. In the first step, 100 g of digested castor wasslurried into 0.5 liters of distilled water. The mixture was mixed for aperiod of 30 minutes with a mechanical stirrer. Aliquots of the slurrythen were centrifuged at 3,400 rpm for a period of approximately 15minutes. The resulting supernatant, which contained the water-solublepolypeptide fraction, was decanted off and used for the foam experimentsin this Example. The remaining water-insoluble sediment was washed withneutral water and again centrifuged. This step was repeated 5 times forthe water insoluble sediment. The water-insoluble sediment washarvested.

The percent solids were measured for the washed, water-insoluble/waterdispersible fraction following drying the sample in an oven. The percentsolids were found to be 16.36%. The water soluble fraction, which wasalso isolated from the first centrifuge cycle (as described above), wasdried in an oven. The dried, water-soluble residue was collected andused to make a 16.36% solids solution for comparison to thewater-insoluble, dispersible fraction. A third 16.36% solids sample wasprepared by mixing 3.272 grams of digested castor, lot 5-108 with 16.728grams of water to yield a 16.36% solids mixture, which inherentlycontains both the water soluble and water-insoluble, dispersiblefractions.

B—Preparation of Polyurethane Foams

A series of polyurethane foams then were prepared by combining anisocyanate, a polyol blend, and the various digested castor polypeptidefractions. The polyol blend used in these experiments was similar tothat described in Example 6 except that the water used contained theisolated fractions of the digested castor protein. Control samples wereprepared at an appropriate water concentration so as to provide the samewater content in all the polyol blends. The various formulations areshown in Table 9.

TABLE 9 Sample Polyol Blend Water Fraction JM-582-1 Distilled WaterJM-582-2 16.36% solution of the soluble fraction of digested castor (lot5-108) JM-582-3 16.36% mixture of digested castor (lot 5-108) (containsboth water-soluble and water-insoluble fractions) JM-582-4 16.36%Water-insoluble/water dispersible fraction of digested castor (lot5-108)

The isocyanate used for the “A” component was RUBINATE-M, polymericdiphenylmethane diisocyanate (PMDI) from Huntsman Corporation. Thecomposition of the polyol blend or “B” component contained 71.4 partsJEFFOL PPG-2000 from Huntsman Corporation, 15.6 parts of Jeffol A-630from Huntsman Corporation, 0.6 JEFFCAT DMDLC from Huntsman Corporation,and 0.6 parts dibutyltin dilaurate from Air Products & Chemicals, Inc,and 2.51 parts distilled water for the control or 3.0 parts of a 16.36%solids containing fraction.

The isocyanate (“A” Component) and polyol blends (“B” Component) weremixed at two ratios, 9 parts “B” to 10 parts “A” and 10 parts “B” to 10parts “A,” which would represent two different isocyanate indexes. Themixtures produced foams having different features. Images of the foamsare shown in FIG. 18, where FIG. 18A represents the samples containing 9parts “B”:10 parts “A” denoted 9/10 PolyI/PMDI, and FIG. 18B representsthe samples containing 10 parts “B”:10 parts “A” denoted 10/10PolyI/PMDI. At both of the polyol/isocyanate ratios, the presence watersoluble polypeptide resulted in polyurethane foams that rosesignificantly and had a smaller cellular structure as compared to thecontrols. The sample containing the water insoluble dispersible fraction(JM-582-4) did not rise as high as the samples containing the watersoluble polypeptide fractions. Without wishing to be bound by theory, itis possible that the increase in height of the foam for the waterinsoluble polypeptide fraction could be attributable to a small amountof water-soluble protein in the water insoluble protein composition.

Example 11 Foam Prepared from Water Soluble Polypeptide CompositionsDerived from Castor Meal or Canola Meal

In this Example, polyurethane foam was prepared using a water-solublepolypeptide composition obtained from castor meal or canola meal.

A—Preparation of Polypeptide Composition

Two samples were prepared under identical conditions, one using wholecanola meal and the other made with whole castor meal. The canolapreparation was prepared as follows: Whole canola meal (Canola Meal MAViterra 00200, reported to contain approximately 37% protein by weight,obtained from Viterra Canola Processing, Step Agatha, MB) was dispersedin a 1.0% sodium hydroxide solution, and was then mixed with a 1 M HClsolution to a final pH value of approximately 4 to 5. Similarly, wholecastor meal (from Kopco Oil Products, Rajkot, India) was dispersed in a1.0% sodium hydroxide solution, and was then mixed with a 1 M HClsolution to a final pH value of approximately 4 to 5.

The castor and canola samples were allowed to sit on the bench top. Thewater-insoluble/water dispersible polypeptide-containing componentsettled while the water soluble polypeptide component was observed as asupernatant. The solids content of the supernatant was determined bydrying samples in an oven. The castor meal supernatant had a solidscontent of 2.85 percent and the canola meal supernatant had a solidscontent of 3.25 percent. For the foam experiments, the canolasupernatant was diluted with distilled water to achieve a solids contentof 2.85%, to be equivalent to that of the castor sample.

B—Preparation of Polyurethane Foam

A series of polyurethane foams were prepared by combining an isocyanate,a polyol blend, and the various supernatant fractions. The polyol blendused in these experiments was similar to that described in Example 10.The control samples were prepared at an appropriate water concentrationso as to provide the same water content in all the polyol blends. Thecomparative formulations are set forth in Table 10.

TABLE 10 Sample Polyol Blend Water Fraction JM-587-1 Distilled WaterJM-587-2 2.85% solution of the soluble fraction of castor meal JM-587-32.85% solution of the soluble fraction of canola meal

The isocyanate used for the “A” component was RUBINATE-M, polymericdiphenylmethane diisocyanate (PMDI)] from Huntsman Corporation. Thecomposition of the polyol blend or “B” component contained 71.4 partsJEFFOL PPG-2000 from Huntsman Corporation, 15.6 parts of Jeffol A-630from Huntsman Corporation, 0.6 JEFFCAT DMDLC from Huntsman Corporation,and 0.6 parts dibutyltin dilaurate from Air Products & Chemicals, Inc,and 2.91 parts distilled water or 3.0 parts of a 2.85% solids containingsoluble fraction.

The isocyanate (“A” Component) and polyol blends (“B” Component) weremixed at a ratio of 7 parts “B” to 10 parts “A.”

Images of the foam produced by the above procedures are shown in FIG.19. The presence of the water soluble polypeptide fractions resulted inpolyurethane foams that rose to a higher height and had a smallercellular structure as compared to the controls that lacked thewater-soluble protein fractions.

Example 12 Foam Prepared Using Water-Soluble Polypeptide CompositionsDerived from Digested Castor Meal

In this Example, polyurethane foam was prepared using a water solublepolypeptide composition obtained from digested castor meal.

Digested castor (Lot 5-108) was fractionated to yield a water-solublefraction, and a water-insoluble/water dispersible fraction using theisolation procedures as reported in Example 10. The supernatant, whichcontained the water-soluble polypeptide fraction, was harvested bydecanting for the foam experiments and the remaining water-insolublesediment, and was harvested into a separate container. In Example 10 thesupernatant fractions were collected and dried in order to make a 16.36%solution of the water soluble polypeptide fraction. In contrast, in thisExample, the supernatant from the first centrifuge cycle was collectedand used as is, without drying. The solids content of the digestedcastor supernatant was determined by drying an aliquot in an oven. Thedigested castor supernatant from the first centrifugation step as foundto have a solids content of 8.93%.

A series of polyurethane foams were prepared by combining an isocyanate,a polyol blend, and the supernatant fraction. The polyol blend used inthese experiments was similar to that described in Example 10. A controlsample was prepared at an appropriate water concentration so as toprovide the same water content in both polyol blends. The variousformulations can be seen in Table 11.

TABLE 11 Sample Polyol Blend Water Fraction JM-561-1 Distilled WaterJM-559-1-2 8.93% solution of the soluble fraction of digested castor(Lot No. 5-108)

The isocyanate (“A” Component) and polyol blends (“B” Component) weremixed at two ratios, 9 parts “B” to 10 parts “A” and 8 parts “B” to 10parts “A,” which would represent two different isocyanate indexes.

The presence of the water soluble polypeptide fractions resulted inpolyurethane foams that rose to a higher height and had a smallercellular structure as compared to the controls. Both mixtures: 9 parts“B” to 10 parts “A” and 8 parts “B” to 10 parts “A” behaved similarly.

Example 13 Foam Prepared Using Whole, Ground Castor Meal or DigestedCastor Meal

In this Example, polyurethane foam was prepared using whole, groundcastor meal or digested castor meal.

Whole canola meal (Canola Meal MA Viterra 00200, reported to containapproximately 37% protein by weight, obtained from Viterra CanolaProcessing, Step Agatha, MB) was ground to an 80 micron particle sizeusing a Retch industrial grinder. Digested castor (Lot 5-108) wasprepared as described in Example 10. In this Example, the whole, groundmeal and the digested castor sample were dry solid powders containingboth a water soluble polypeptide composition and a water insoluble/waterdispersible polypeptide composition.

Polyurethane foams were prepared by combining an isocyanate, a polyolblend, and adding the dry castor particles to the polyol blend. Thepolyol blend used in these experiments was similar to that described inExample 6.

Specifically, two comparative cup foam samples were prepared. A firstsample, JM-560-1, was prepared by adding 9 grams the polyol blenddescribed in Example-6 (sample JM-37-1) into a 250 mL disposable beakerand then adding 1 gram of the 80 micron ground whole castor meal intothe polyol blend. After the protein was added to the polyol blend, thecomposition was mixed using a spatula and a vortex mixer to disperse theprotein. The total sample weight for the polyol/protein “B” componentswas 10 grams. Then, 10 grams of component “A” (PMDI) was added to the“B” component in the beaker and was mixed thoroughly by hand with aspatula, and then allowed to rise freely in the beaker.

A second sample, JM-555-3, was prepared by adding 9 grams the polyolblend described in Example 6 (sample JM-37-1) into a 250 mL disposablebeaker and then adding 2 grams digested castor (Lot No. 5-108) into thepolyol blend. After the protein was added to the polyol blend, thecomposition was mixed using a spatula and a vortex mixer to disperse theprotein. The total sample weight for the polyol/protein “B” componentswas 10 grams. Then, 10 grams of component “A” (PMDI) was added to the“B” component in the beaker and was mixed thoroughly by hand with aspatula, and then allowed to rise freely in the beaker.

The two samples were compared to a control foam (JM-37-1) which did notcontain the added dry protein containing powders.

The presence of the protein containing powders resulted in polyurethanefoams that rose to a higher height and had a smaller cellular structureas compared to the controls.

Example 14 Characterization of Mixture Formed by Addition of ProteinComposition to a Polyol Composition

Polyol compound PPG 200 and a protein composition (e.g., digestedcastor, digested soy, and digested whey) were mixed together in thepresence and absence of water for the purposes of investigating whetheror not certain chemical reactions might occur between these components.In particular, because FTIR analyses indicated the presence of freecarboxylic acid functionality in the digested proteins, studies wereconducted to try and identify the existence of esterification reactionsbetween the hydroxyl end groups of the polyol and the free acid moietiesof the digested proteins. This was conducted in the absence of theisocyanate component so that the potential reaction could be isolated.The procedures used for mixing the polyol and protein composition arereported in Example 5, along with physical observations of thepolyol/protein mixture.

Upon completing the mixing procedure, the sample jars were allowed toset under ambient conditions for several days. Once the precipitatedcomponents from the various mixtures had settled to the bottom of thecontainers, aliquots of the supernatants were retrieved together withcertain samples of the precipitated products. The resulting aliquotswere analyzed via solution state FTIR, and subtraction spectra werecreated for the purposes of testing for the presence or absence ofextracted and/or reacted components

The subtraction spectra were created by subtracting the spectrum of neatPPG2000 from the supernatant spectra (multiplicative factors=1). Theresulting subtraction spectra were then overlaid and compared to thestarting ingredients (PPG2000 and digested proteins) for the purpose oftesting for the possibility of a chemically transformed reactionproduct.

A subtraction spectrum of the supernatant from the mixture that was madewith digested castor in polyol with water revealed the presence of acompound in the supernatant. By comparing the subtraction spectrum tothe spectrum for neat digested castor, it was found that the supernatantcompound possessed predominant absorption bands at approximately 3540cm⁻¹ and 3423 cm⁻¹. The 3423 cm⁻¹ group appeared only as a shoulder inthe starting digested castor compound (the predominant N—H stretch inthe digested castor appeared at approximately 3270 cm⁻¹). In addition,the predominant N—H band in the neat digested castor was absent in thesupernatant compound. Moreover, although the supernatant-compoundcontained the dominant digested castor band centered near 1638 cm⁻¹,there was no evidence of the carbonyl at 1717 cm⁻¹ (the absorbance at1717 cm⁻¹ in the digested castor is consistent with the presence of afree carboxylic acid). Instead, the supernatant compound showed thepresence of a significantly different carbonyl stretch at 1739 cm⁻¹,which is consistent with the presence of an ester.

Importantly, the ratio of the absorbance intensity for the peak near1639 cm⁻¹ to that of the ester peak near 1739 cm⁻¹ was determined to beapproximately 2/1, which was nearly the same for the comparable ratio ofthe 1639 cm⁻¹ peak in digested castor to that of the carbonyl peak near1717 cm⁻¹. In addition, the 1531 cm⁻¹ peak that appears in the digestedcastor spectrum was missing from the supernatant compound. Thesupernatant exhibits the presence of water as evidenced by the broadpeak near 3550 cm⁻¹, and by the assembly of peaks between 2300 cm⁻¹ and1900 cm⁻¹.

An overlay of the supernatant compound spectrum with that of PPG 2000polyol shows that the polyol hydroxyl peak centered near 3474 cm-1 isdistinctly absent in the supernatant compound. Collectively, thesespectral comparisons show that the supernatant compound is either asolubilized fractional component of the starting digested castor proteinitself, or a solubilized reaction product between a digested castorcomponent and the polyol compound.

In order to determine the potential effect of water on these findings,the supernatant of the analogous mixture with digested castor andPPG2000 was made in the absence of water. No compound was detected inthe supernatant. The material that precipitated out of the JM-69-2sample (See Example 5) was separately collected and analyzed via FTIR,and its spectrum was overlaid with that of the starting digested castormaterial, and that of the PPG 2000 polyol. Analysis of the spectrarevealed that the precipitate was quite similar in composition to thestarting digested castor protein. The precipitate was not washed, and itcontained a spectral component at 1092 cm⁻¹ is consistent with thepresence of a polyol impurity.

In analogous experiments with digested whey and digested soy proteins,the supernatants were similarly collected and analyzed via FTIR. Theresulting subtraction spectra, when overlayed with that of thesupernatant compound that was made with digested castor, show that thesupernatant compounds appear to have strikingly similar structuralattributes. These similarities are further exemplified by overlays ofthe hydroxyl region, and the carbonyl region.

As discussed in Example 5, the bulk addition of digested proteins topolyurethane foam formulations (approximately 5% by weight of the foam)led to a surprising decrease in foam density. In light of thisobservation, and in light of the striking similarities between thesupernatant compounds as seen by FTIR, studies were conducted to producefoamed polyurethane formulations by using the supernatants compounds inplace of the bulk proteins themselves. The foams that were made with thesupernatant compounds were all surprisingly low in density. Thus,although bulk-addition of the preferred digested proteins can lead tofavorable results, similar results can be surprisingly achieved byvirtue of the low-concentration addition of a compound with structuralattributes like those found in the supernatants from the presentexample. Thus, the trend observed by means of the bulk-addition ofdigested proteins was reproduced by means of simply adding the solvatedsupernatant compounds in the absence of the water-insoluble proteinfractions (i.e., the water-soluble fractions as extracted from thedigested protein using a mixture of polyol and water) produced thedesired effect of density reduction in the absence of thewater-insoluble fraction that precipitated from the polyol/water blend.

INCORPORATION BY REFERENCE

The entire disclosure of each of the patent documents and scientificarticles referred to herein is incorporated by reference for allpurposes.

EQUIVALENTS

The invention may be embodied in other specific forms without departingfrom the spirit or essential characteristics thereof. The foregoingembodiments are therefore to be considered in all respects illustrativerather than limiting the invention described herein. Scope of theinvention is thus indicated by the appended claims rather than by theforegoing description, and all changes that come within the meaning andrange of equivalency of the claims are intended to be embraced therein.

1-9. (canceled)
 10. A polyurethane foam having reduced density due tothe presence of protein containing composition, said polyurethane foamcomprising a reaction product of a mixture comprising: (a) anisocyanate-based reactant; (b) an optional isocyanate-reactive compound;and the protein containing composition enriched in water-solublepolypeptides so the protein containing composition reduces the densityof the polyurethane foam by at least 5% relative to a polyurethane foamproduced from the same mixture but lacking the protein containingcomposition.
 11. A polyurethane foam comprising a reaction product of amixture comprising (a) an isolated protein containing composition,wherein the protein is capable of dispersing PMDI in an aqueous medium;(b) an isocyanate-based reactant; and (c) an optionalisocyanate-reactive compound.
 12. The polyurethane foam of claim 10,wherein the isocyanate-based reactant is an organic polyisocyanate. 13.The polyurethane foam of claim 12, wherein the organic polyisocyanate ispolymeric diphenylmethane diisocyanate, 2,4-tolylene diisocyanate,2,6-tolylene diisocyanate, benzene diisocyanate, m-xylylenediisocyanate, 1,4-phenylene diisocyanate, 1,3-phenylene diisocyanate,4,4′-diphenyl diisocyanate, 4,4′-diphenyldimethylmethane diisocyanate,hexamethylene diisocyanate, tolidine diisocyanate, dianisidinediisocyanate, 1,5-naphthalene diisocyanate, 1,4-cyclohexanediisocyanate, or a combination thereof.
 14. The polyurethane foam ofclaim 10, wherein the isocyanate-based reactant comprises a urethane,allophanate, urea, biuret, carbodiimide, uretonimine, isocyanurate, or acombination thereof.
 15. The polyurethane foam of claim 10, wherein theisocyanate-based reactant is polymeric diphenylmethane diisocyanate. 16.(canceled)
 17. The polyurethane foam of claim 10, wherein theisocyanate-reactive compound is present and is a compound having ahydroxyl group or an amino group capable of reacting with theisocyanate.
 18. The polyurethane foam of claim 17, wherein theisocyanate-reactive compound is a polyol.
 19. (canceled)
 20. (canceled)21. (canceled)
 22. The polyurethane foam of claim 17, wherein theisocyanate-reactive compound is polyoxypropylene glycol, polypropyleneoxide-ethylene oxide, propylene glycol, propane diol, glycerin, an aminealkoxylate, or a mixture thereof.
 23. (canceled)
 24. The polyurethanefoam of claim 10, wherein the mixture further comprises a surfactant.25. The polyurethane foam of claim 10, wherein the foam has a density inthe range of from about 0.01 g/cm³ to about 0.5 g/cm³ as determined byASTM D-7487.
 26. The polyurethane foam of claim 10, wherein the foam hasa density that is from 5% to 80% less dense than a foam created from thesame starting composition lacking the protein containing composition.27. The polyurethane foam of claim 10, wherein the foam cream time, asdefined by ASTM D-7487, is less than one minute.
 28. The polyurethanefoam of claim 10, wherein the foam free rise height, as determined byASTM D7487, is greater than the foam free rise height of a foam createdfrom the same starting composition lacking the protein containingcomposition.
 29. The polyurethane foam of claim 28, wherein the foamfree rise height is at least 5% greater than the foam free rise heightof a foam created from the same starting composition lacking the proteincontaining composition.
 30. The polyurethane foam of claim 10, whereinthe foam has a larger number of small, uniform cells when compared to afoam created from the same starting composition lacking the proteincontaining composition.
 31. A method of producing a polyurethane foamhaving reduced density due to the presence of protein containingcomposition, said polyurethane foam, comprising the steps of: (a) mixinga protein containing composition and an isocyanate-based reactant toproduce a mixture; and (b) permitting the mixture to produce apolyurethane foam, wherein the protein containing composition isenriched in water-soluble polypeptides in order to reduce the density ofthe polyurethane foam by at least 5% relative to a polyurethane foamproduced from the same mixture but lacking the protein containingcomponent.
 32. The method of claim 31, wherein the water-solublepolypeptides comprise one or more of the following features: (a) anamide-I absorption band between about 1633 cm⁻¹ and 1680 cm⁻¹, asdetermined by solid state FTIR; (b) an amide-II band betweenapproximately 1522 cm⁻¹ and 1560 cm⁻¹, as determined by solid stateFTIR; (c) two prominent 1° amide N—H stretch absorption bands centeredat about 3200 cm⁻¹, and at about 3300 cm⁻¹, as determined by solid stateFTIR; (d) a prominent cluster of protonated nitrogen nuclei defined by¹⁵N chemical shift boundaries at about 94 ppm and at about 100 ppm, and¹H chemical shift boundaries at about 7.6 ppm and at about 8.1 ppm, asdetermined by solution state, two-dimensional proton-nitrogen coupledNMR; (e) an average molecular weight of between about 600 and about2,500 Daltons; or (f) an inability to stabilize an oil-in-wateremulsion, wherein, when an aqueous solution comprising 14 parts byweight of protein dissolved or dispersed in 86 parts by weight of wateris admixed with 14 parts by weight of PMDI, the aqueous solution and thePMDI produce an unstable suspension that macroscopically phase separatesunder static conditions within five minutes after mixing.
 33. (canceled)34. The method of claim 31, wherein the isocyanate-based reactant is anorganic polyisocyanate.
 35. The method of claim 34, wherein the organicpolyisocyanate is polymeric diphenylmethane diisocyanate, 2,4-tolylenediisocyanate, 2,6-tolylene diisocyanate, benzene diisocyanate,m-xylylene diisocyanate, 1,4-phenylene diisocyanate, 1,3-phenylenediisocyanate, 4,4′-diphenyl diisocyanate, 4,4′-diphenyldimethylmethanediisocyanate, hexamethylene diisocyanate, tolidine diisocyanate,dianisidine diisocyanate, 1,5-naphthalene diisocyanate, 1,4-cyclohexanediisocyanate, or a combination thereof. 36-45. (canceled)
 46. The methodof claim 31, wherein the mixture in step (a) further comprises a blowingagent or a compound that forms a blowing agent.
 47. The method of claim46, wherein the compound that forms the blowing agent is water. 48-57.(canceled)
 58. A premix for preparing a polyurethane foam of claim 10having reduced density due to the presence of protein containingcomposition, said premix, comprising: (a) a protein containingcomposition enriched in water-soluble polypeptides; and (b) anisocyanate-based reactant, wherein the protein containing composition isenriched in water-soluble polypeptides in order to reduce the density ofthe polyurethane foam by at least 5% relative to a polyurethane foamproduced from the same mixture but lacking the protein containingcomponent.
 59. (canceled)
 60. The premix of claim 58, wherein theisocyanate-based reactant is an organic polyisocyanate.
 61. The premixof claim 60, wherein the organic polyisocyanate is polymericdiphenylmethane diisocyanate, 2,4-tolylene diisocyanate, 2,6-tolylenediisocyanate, benzene diisocyanate, m-xylylene diisocyanate,1,4-phenylene diisocyanate, 1,3-phenylene diisocyanate, 4,4′-diphenyldiisocyanate, 4,4′-diphenyldimethylmethane diisocyanate, hexamethylenediisocyanate, tolidine diisocyanate, dianisidine diisocyanate,1,5-naphthalene diisocyanate, 1,4-cyclohexane diisocyanate, or acombination thereof. 62-77. (canceled)
 78. An article comprising thefoam of claim
 10. 79. The polyurethane foam of claim 10, wherein theprotein containing composition further comprises a protein capable ofdispersing PMDI in an aqueous medium.
 80. (canceled)
 81. Thepolyurethane foam of claim 10, wherein the water-soluble polypeptidescomprise one or more of the following features: (a) an amide-Iabsorption band between about 1633 cm⁻¹ and 1680 cm⁻¹, as determined bysolid state FTIR; (b) an amide-II band between approximately 1522 cm⁻¹and 1560 cm⁻¹, as determined by solid state FTIR; (c) two prominent 1°amide N—H stretch absorption bands centered at about 3200 cm⁻¹, and atabout 3300 cm⁻¹, as determined by solid state FTIR; (d) a prominentcluster of protonated nitrogen nuclei defined by ¹⁵N chemical shiftboundaries at about 94 ppm and at about 100 ppm, and ¹H chemical shiftboundaries at about 7.6 ppm and at about 8.1 ppm, as determined bysolution state, two-dimensional proton-nitrogen coupled NMR; (e) anaverage molecular weight of between about 600 and about 2,500 Daltons;or (f) an inability to stabilize an oil-in-water emulsion, wherein, whenan aqueous solution comprising 14 parts by weight of protein dissolvedor dispersed in 86 parts by weight of water is admixed with 14 parts byweight of PMDI, the aqueous solution and the PMDI produce an unstablesuspension that macroscopically phase separates under static conditionswithin five minutes after mixing.
 82. The polyurethane foam of claim 10,wherein the protein containing composition is derived from biomassselected from the group consisting of whey, corn, wheat, sunflower,cotton, rapeseed, canola, castor, soy, camelina, flax, jatropha, mallow,peanuts, tobacco, algae, sugarcane bagasse, and combinations thereof.83. The method of claim 31, wherein the protein containing compositionis derived from biomass selected from the group consisting of whey,corn, wheat, sunflower, cotton, rapeseed, canola, castor, soy, camelina,flax, jatropha, mallow, peanuts, tobacco, algae, sugarcane bagasse, andcombinations thereof.
 84. The polyurethane foam of claim 81, wherein theprotein containing composition is derived from biomass selected from thegroup consisting of whey, corn, wheat, sunflower, cotton, rapeseed,canola, castor, soy, camelina, flax, jatropha, mallow, peanuts, tobacco,algae, sugarcane bagasse, and combinations thereof.
 85. The polyurethanefoam of claim 10, wherein the protein containing composition is derivedwhey, canola, castor, or soy.
 86. The polyurethane foam of claim 10,wherein the protein containing composition is a mixture of water-solublepolypeptide composition and water-insoluble/water-dispersiblepolypeptide composition enriched in water-soluble polypeptidecomposition to reduce the density of the polyurethane foam by at least5% relative to a polyurethane foam produced from the same mixture butlacking the protein containing component.